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PRIVATE CARS

C5-SYNERGIE
The technical information contained in this document is intended for the exclusive use of the trained personnel of the motor vehicle repair trade. In some instances, this information could concern the security and safety of the vehicle. The information is to be used by the professional vehicle repairers for whom it is intended and they alone would assume full responsibility to the exclusion of that of the manufacturer. The technical information appearing in this brochure is subject to updating as the characteristics of each model in the range evolve. Motor vehicle repairers are invited to contact the CITRON network periodically for further information and to obtain any possible updates.

2002

CAR 050011 Volume 2

PRESENTATION

THIS HANDBOOK summarises the characteristics, adjustments, checks and special features of CITROEN vehicles, not including COMMERCIAL vehicles for which there exists a separate handbook. The handbook is divided into nine groups representing the main functions : GENERAL - ENGINE - INJECTION - IGNITION - CLUTCH, GEARBOX, DRIVESHAFTS - AXLES, SUSPENSION, STEERING - BRAKES - ELECTRICAL AIR CONDITIONING. In each section, the vehicles are dealt with in the following order : C5 - SYNERGIE and all models where applicable. The information given in this handbook is based on vehicles marketed in EUROPE.

IMPORTANT

If you find that this handbook does not always meet your requirements, we invite you to send us your suggestions which we will take into account when preparing future publications. For example : INSUFFICIENT INFORMATION SUPERFLUOUS INFORMATION NEED FOR MORE DETAILS

Please send your comments and suggestions to : CITROEN U.K. Ltd. 221, Bath Road, SLOUGH, SL1 4BA. U.K.

IDENTIFICATION OF VEHICLES

(A) Chassis stamp (cold stamp on bodywork). (B) Manufacturers data plate. (under the rear bench seat) GENERAL (C) A-S / RP No. and RP paint code (label on front pillar close to drivers door). (D) Inflation pressures and tyre references. (label on front pillar close to drivers door) (E) Serial no. on bodywork. (F) Gearbox reference Factory serial no. (G) Engine legislation type Factory serial no

E1APO8RD

C5 - All Types

IDENTIFICATION OF VEHICLES
Petrol saloons 1.8i 16V Automatic X-SX 2.0i 16V Automatic X-SX-Exclusive L4 DC 6FZE L5 DC RFNC/IF L4 DC RFNB RFN 1997 8 AL4 20 TP 44 BE4/5 20 BL 30 9 AL4 20 TP 42 L5 DC RFNE

Emission standard

L4 DC 6FZB

L5 DC 6FZC/IF 6FZ 1749 7 BE4/5 20 DL 29

GENERAL

Type code Engine type Cubic capacity (cc) Fiscal rating (hp) Gearbox type Gearbox ident. plate

IDENTIFICATION OF VEHICLES
Petrol saloons 2.0 HPi 30.i 24V V6

C5 - All Types

Automatic Exclusive
Emission standard Type code Engine type Cubic capacity (cc) Fiscal rating (hp) Gearbox type Gearbox ident. plate

L4 DC RLZB RLZ 1997 8 BE4/5 20 DL31 ML/5C 20 LM 21 13 DC XFXC/IF

L5 DC XFXF/IF XFX 2946 14 ML/5T 20 LE 95 4 HP 20 20 HZ 13 GENERAL

C5 - All Types

IDENTIFICATION OF VEHICLES
Diesel saloons 2.0 HDi Automatic X X-Exclusive L4 DC RHYB RHY 6 BE4/5 20 DL 32 ML/5C 20 LM 18 ML/5T (*) 20 LE 94 DC RHSB RHS 1997 7 AL4 20 TP 43 ML/5C 20 LM 18 6 ML/5T 20 LE 94 7 AL4 20 TP 43 DC RHSE DC RHZB RHZ DC RHZE Automatic

Emission standard

GENERAL

Type code Engine type Cubic capacity (cc) Fiscal rating (hp) Gearbox type Gearbox ident. plate

(*) FAP = Particle filter

IDENTIFICATION OF VEHICLES
Diesel saloons 2.2 HDi

C5 - All Types

Automatic SX-Exclusive
Emission standard Type code Engine type Cubic capacity (cc) Fiscal rating (hp)

L4 DC 4HXB 4HX 2179 8 ML/5C 20 LM 17 ML/5T 20 LE 96 4 HP 20 20 HZ 20 DC 4HXE GENERAL

Gearbox type
Gearbox ident. plate

C5 - All Types

IDENTIFICATION OF VEHICLES
Petrol estates 1.8i 16V 2.0i 16V Automatic X-SX SX Exclusive
L5 DE 6FZB 6FZ 1749 7 BE4/5 20 DL 29 20 DL 30 9 AL4 ? DE RFNC/IF RFN 1997 8 BE4/5 20 DL 31 ML/5C 20 LM 21 13 ML/5T 20 LE 95 DE RFNE L4 DE RLZB RLZ DE XFX/IF XFX 2946 14 4 HP 20 20 HZ 13

2.0 HPi

3.0i 24V V6 Automatic Exclusive


L5 DE XFXF/IF

GENERAL

Emission standard Type code Engine type Cubic capacity (cc) Fiscal rating (hp) Gearbox type Gearbox ident. plate

L4 DE 6FZC/IF

IDENTIFICATION OF VEHICLES
Diesel estates 2.0 HDi Automatic X
Emission standard Type code Engine type Cubic capacity (cc) Fiscal rating (hp) Gearbox type Gearbox ident. plate

C5 - All Types

Automatic

X-Exclusive L4 GENERAL

DE RHYB RHY 6 BE4/5 20 DL 32 ML/5C

DE RHSB RHS

DE RHSE 1997 7 ML/5T AL4 20 TP 43 (*) ML/5C

DE RHZB RHZ 6 ML/5T 20 LE 94 20 LM 18

DE RHZE

7 AL4 20 TP 48 (*)

20 LM 18

20 LE 94 (*)

(*) FAP = Particle filter

C5 - All Types

IDENTIFICATION OF VEHICLES
Diesel estates 2.2 HDi Automatic SX-Exclusive

Emission standard

L4 DE 4HXB 4HX 2179 8 ML/5C 20 LM 17 ML/5T 20 LE 96 4 HP 20 20 HZ 20 DE 4HXE

GENERAL

Type code Engine type Cubic capacity (cc) Fiscal rating (hp)

Gearbox type
Gearbox ident. plate

IDENTIFICATION OF VEHICLES

SYNERGIE - All Types

1 2 3 4

Manufacturers cold stamp R.P. organisation No. Paint code 01/02/99 # Label : - Tyre pressures. - R.P. Organisation No. - Paint code. Gearbox ident. Engine plate Manufacturers plate GENERAL

5 6 7

E1AP07GD

IDENTIFICATION OF VEHICLES
Petrol 2.0i 16 V Automatic X SX Exclusive GENERAL
Emission standard Type code Engine type Cubic capacity (cc) Fiscal rating (hp) Gearbox type Gearbox ident. plate IF L5 (*)

SYNERGIE - All Types


Diesel 2.0 HDi 2.0 16 V HDi

X SX
L3

X Taxi SX Exclusive
L4

AF RFNC/IF RFN

AF RFNF/IF

AF RHZA/T RHZ 1997

AF RHZA

AF RHWB RHW

9 BE4/5 DL26 - DL27

10 AL4 20 TP 31

6 ML5 20 LE 91

(*) IF = Fiscal incentive L5 (EURO4). 10

CAPACITIES
Draining method. The oil capacities are defined according to the following methods. 1) - Vehicle on level surface (in high position, if equipped with hydropneumatic suspension). 2) - Engine warm (oil temperature 80C). 3) - Draining of the oil sump + removal of the cartridge (duration of draining + dripping = 15 mm). 4) - Refit plug + cartridge. 5) - Engine filling. 6) - Engine starting (allowing the cartridge to be filled). 7) - Engine stopped (stationary for 5 mm).

ALL TYPES

ESSENTIAL : Systematically check the oil level using the oil dipstick.

11

GENERAL

C5 - All Types

CAPACITIES (in litres)


C5 Petrol 1.8i 16V Automatic 2.0i 16V Automatic RFN 4.25 1.7 1.8 6 3 1.8 6 3 1.8 8.3 5.3 RLZ XFX 5.25 2 2.0 HPi 3.0i V6 Automatic

Engine type Engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox After oil change Braking circuit Hydraulic circuit Cooling system Fuel tank capacity

6FZ

GENERAL

4.3 8.8 9.3 (*) 66 8.8 14

(*) = With automatic gearbox ESSENTIAL : Systematically check the oil level using the oil dipstick 12

CAPACITIES (in litres)


C5 Diesel 2.0 HDi Automatic
Engine type Engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox After oil change Braking circuit Hydraulic circuit Cooling system Fuel tank capacity

C5 - All Types

2.2 HDi Automatic RHZ 4HX GENERAL 4.75 1.5 1.8 1.8 8.3 - 6 (1) 5.3 3 (1) 8.3 5.3 Automatic

RHY

RHS 4.75 1.5 1.8 8.3 - 6 (1) 5.3 3 (1) 4.5 (1) 1.7 (1)

4.3 10.7 11.7 (With additional heating) 68

(1) = With air conditioning. ESSENTIAL : Systematically check the oil level using the oil dipstick. 13

SYNERGIE - All Types


Petrol 2.0i 16V

CAPACITIES (in litres)


Synergie Diesel 2.0 HDi Automatic 2.0 HDi 16V

Engine type

RFN

RHZ 21

RHW

GENERAL

Engine angle Engine with filter change Between Min. and Max. 5-speed gearbox Automatic gearbox After oil change Hydraulic or brake circuit Cooling system Fuel tank capacity

4.25 1.7 1.8 8 3

4.5 1.4 1.8

4.75 1.9

Without ABS : 0.47 - With ABS : 0.52 7 80 - ESSENTIAL : Systematically check the oil level using the oil dipstick. 14 8.5 80

(1) With air conditioning.

LUBRICANTS - TOTAL recommended oils


S.A.E. Norm - Table for selection of engine oil grade

ALL TYPES

E4AP006D

15

GENERAL

ALL TYPES
Factory evolutions in 2001 model year

LUBRICANTS - TOTAL recommended oils


ESSENTIAL : For all vehicles with a 30,000 km (20,000 miles) maintenance interval, use exclusively TOTAL ACTIVA/QUARTZ 7000 or 9000 or any other oils offering identical specifications to these. These oils offer specifications that are superior to those defined by norms ACEA A3/98 or API SJ. Failing this, it is essential to adhere to the maintenance programmes covering severe operating conditions. 5W30 cannot be used in the following engines: XU10J4RS : XSARA VTS 2.0i 16V (3 doors). SOFIM : RELAY 2.8 D and 2.8 TD. 1580 SPI : DISPATCH 1.6i. 2.0 and 2.2 HDi engines equipped with particle filter. WARNING : CITRON engines prior to model year 2000 do not have to be lubricated with oils adhering to the norms ACEA A198/B1-98 and API SJ/CF EC.

CITRON engines are lubricated at the factory with TOTAL oil of grade S.A.E.5W-30. TOTAL oil of grade S.A.E.5W-30 allows improved fuel economies (approx 2.5%). Features of CITRON C5 : 2.0 and 2.2 HDi engines have a particle filter. The maintenance interval for normal operation is 30,000 km (20,000 miles) for petrol engines. WARNING : HDi engines are high technology engines which imperatively require use of quality SYNTHETIC OILS : TOTAL ACTIVA or TOTAL QUARTZ 5W40. To maintain engine performances, all countries in Europe should observe this requirement. NOTE : Only PORTUGAL and GREECE may use 10W40 semisynthetic oil. GENERAL

16

LUBRICANTS - TOTAL recommended oils


Selection of engine oil grades recommended for climatic conditions in countries of distribution

ALL TYPES

ACEA Norms The first letter corresponds to the type of engine concerned : A : petrol and dual fuel petrol / LPG engines. B : diesel engines. The figure following the first letter corresponds to the type of oil. 1 : highly fluid oils, for reducing friction and lowering fuel consumption. 3 : high performance oils. The number after that (96 or 98) corresponds to the year of creation of the norm. NOTE : From 01/03/2000, all engine oils must comply with ACEA98 norms. Example : ACEA A1-98 / B1-98 : Blended oils for all engines, permetting fuel economy (complying with ACEA 98 norms).

API Norms The first letter corresponds to the type of fuel used by the engine : S : petrol and dual fuel petrol / LPG engines. C : diesel engines. The second letter corresponds to the degree of evolution, in ascending order. Example : The norm SJ is more severe than the norm SH and corresponds to a higher level of performance. The adding of the letters EC indicates that the engine oil concerned is an oil which permits fuel economy. EC : Energy Conserving, reduction in fuel consumption. Examples : API SJ / CF : Blended oils for diesel and dual fuel petrol / LPG engines API CF / EC : Oils specifically for diesel engines, permitting fuel economy. API SJ / CF / EC : Blended oils for all engines, permetting fuel economy. 17 GENERAL

ALL TYPES

LUBRICANTS - TOTAL recommended oils

Engine oil norms. Norms in force. These engine oils have been classified by the following recognised organisations: S.A.E. : Society of Automotive Engineers. API : American Petroleum Institute. ACEA : Association des Constructeurs Europens dAutomobiles. Recommendations. Denominations of TOTAL oils, according to country of marketing: TOTAL ACTIVA (France only). TOTAL QUARTZ (Outside France). ESSENTIAL : To preserve engine performances, all engines fitted in CITROEN vehicles must be lubricated with high quality oils (synthetic or semi-synthetic) Summary Engine oil norms to be respected in 2001 model year. Model year AM 2001 Types of engine Petrol and dual fuel petrol / LPG engines Diesel engines ACEA norms A3-98 or A1-98 (*) B3-98 or B1-98 (*) API norms SJ or SJ / EC (*) CF or CF / EC (*)

GENERAL

(*) = It is essential not to use engine oils respecting these norms for the following engine-types . XU10J4RS. 1580 SPI. SOFIM 2.8 D et SOFIM 2.8 TD. 18

LUBRICANTS - TOTAL recommended oils


S.A.E. grades TOTAL ACTIVA 9000 TOTAL QUARTZ 9000 TOTAL ACTIVA 9000 (*) TOTAL QUARTZ 9000 (*) TOTAL ACTIVRAC (*) = Blended oils for all engines, permitting fuel economy. SPI norms Blended oils for all engines (petrol, dual-fuel petrol / LPG and diesel) 5W-40 5W-30 10W-40 SJ / CF SJ / CF EC SJ / CF

ALL TYPES
ACEA norms

A3-98 / B3-98 A1-98 / B1-98 A3-98 / B3-98 GENERAL

Oils specifically for petrol and dual-fuel petrol / LPG engines TOTAL ACTIVA 7000 TOTAL QUARTZ 7000 TOTAL QUARTZ 9000 TOTAL ACTIVA 7000 TOTAL QUARTZ 7000 TOTAL ACTIVA DIESEL 7000 TOTAL QUARTZ DIESEL 7000 TOTAL ACTIVA DIESEL 7000 TOTAL ACTIVA DIESEL 9000 19 10W-40 0W-40 15W-50 Oils specifically for diesel engines 10W-40 15W-50 5W-40 CF B3-98 SJ A3-98

ALL TYPES

LUBRICANTS - TOTAL recommended oils


FRANCE Blended oils for all engines, supplied in bulk

Metropolitan FRANCE

TOTAL ACTIVRAC TOTAL ACTIVA Blended oils for all engines

S.A.E : 10W-40 Norms TOTAL ACTIVA DIESEL Oils specifically for diesel engines 7000 10 W-40 9000 5W-40

Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10 W-40

GENERAL

Metropolitan FRANCE New Caledonia Guadeloupe Saint-Martin La Runion Martinique Guyana Tahiti Mauritius Mayotte

900 5W-40 (*) 9000 5W-30 (**)

9000 5W-40

7000 15W-50

7000 15W-50

(*) = HDi FAP (Particle filter) - (**) = Blended oils for all engines, permitting fuel economy. 20

LUBRICANTS - TOTAL recommended oils


EUROPE TOTAL QUARTZ (*) = Blended oils for all engines, permitting fuel economy Germany Austria Belgium Bulgaria Cyprus Croatia Denmark Spain Finland Great Britain Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 9000 7000 7000 9000 7000 7000 7000 7000 9000 7000 7000 7000 7000 9000 7000 21 10W-40 0W-40 10W-40 10W-40 0W-40 10W-40 15W50 10W-40 10W-40 0W-40 10W-40 15W-50 10W-40 10W-40 0W-40 10W-40

ALL TYPES
TOTAL QUARTZ DIESEL Oils specifically for diesel engines

9000 5W-40 9000 5W-30 (*)

7000 10W-40

GENERAL

ALL TYPES

LUBRICANTS - TOTAL recommended oils


EUROPE (continued) TOTAL QUARTZ TOTAL QUARTZ DIESEL Oils specifically for diesel engines

(*) = Blended oils for all engines, permitting fuel economy Greece Holland Hungary Italy Ireland Iceland Latvia Lithuania Macedonia Malta Moldova Norway Poland Portugal Slovak Republic GENERAL

Blended oils for all engines

Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 7000 7000 9000 10W-40 15W-50 10W-40 0W-40

7000 10W-40 9000 5W-40 9000 5W-30 (*) 7000 9000 7000 7000 7000 7000 7000 9000 10W-40 0W-40 10W-40 10W-40 15W-50 10W-40 10W-40 0W-40

7000 10W-40

7000 10W-40 22

LUBRICANTS - TOTAL recommended oils


EUROPE (continued) TOTAL QUARTZ (*) = Blended oils for all engines, permitting fuel economy Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W-40 9000 0W-40

ALL TYPES
TOTAL QUARTZ DIESEL Oils specifically for diesel engines

Czech Republic Romania Russia Slovenia Sweden Switzerland Turkey Ukraine Yugoslavia 23 9000 5W-40 9000 5W-30 (*)

7000 10W-40 9000 0W-40 7000 10W-40 7000 10W-40 9000 0W-40 7000 10W-40 7000 10W-40 7000 15W-50 9000 0W-40 7000 10W-40 9000 0W-40 7000 10W-40 7000 10W-40

GENERAL

7000 10W-40 7000 15W-50

ALL TYPES

LUBRICANTS - TOTAL recommended oils


TOTAL QUARTZ Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W-40 TOTAL QUARTZ DIESEL Oils specifically for diesel engines

Australia New-Zealand Ivory Coast Egypt Gabon Madagascar Morocco Senegal Tunisia Argentina Brazil, Chile Cuba Mexico Paraguay Uruguay GENERAL

OCEANIA

AFRICA 9000 5W-40 7000 15W-50 7000 10W-40

CENTRAL AND SOUTH AMERICA

24

LUBRICANTS - TOTAL recommended oils


TOTAL QUARTZ (*) = Blended oils for all engines, permitting fuel economy China South Korea Hong Kong India Indonesia Japan Malaysia Pakistan Philippines Singapore Tawan Thaland Vietnam 25 SOUTH EAST ASIA 9000 5W-40 9000 5W-30 9000 5W-40 Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines 7000 10W-40 7000 15W-50

ALL TYPES
TOTAL QUARTZ DIESEL Oils specifically for diesel engines

7000 15W-50 7000 10W-40 7000 15W-50 7000 10W-40

7000 15W-50 9000 5W-40 7000 10W-40 7000 15W-50 7000 15W-50

GENERAL

7000 10W-40

ALL TYPES

LUBRICANTS - TOTAL recommended oils


TOTAL QUARTZ Blended oils for all engines Oils specifically for petrol and dual-fuel petrol / LPG engines TOTAL QUARTZ DIESEL Oils specifically for diesel engines

Saudi Arabia Bahrain Dubai United Arab Emirates Iran Israel Jordan Kuwait Lebanon Oman Qatar Yemen 26 MIDDLE EAST 9000 5W-40 7000 15W-50 7000 10W-50 GENERAL

LUBRICANTS - TOTAL recommended oils


Gearbox oils

ALL TYPES
TOTAL TRANSMISSION BV Norms S.A.E 75W-80 Special oil distributed by CITRON (Part No. 9730 A2) TOTAL FLUIDE ATX or TOTAL FLUIDE AT 42. Special oil distributed by CITRON (Part No. 9730 A3). Special oil distributed by CITRON (Part No. 9736 22). TOATAL TRANSMISSION X 4

Manual gearbox

4 HP 20 and AL4 automatic gearboxes Transfer box and rear axle

Power steering oils All countries Power- assisted steering Very cold countries TOTAL FLUIDE ATX TOTAL FLUIDE DA Special oil distributed by CITRON (Part No. 9730 A1)

27

GENERAL

MB3 automatic gearbox

All countries

ALL TYPES

LUBRICANTS - TOTAL recommended oils


Engine coolant fluid Packs CITROEN Fluid 2 litres 5 litres 20 litres 210 litres Synthetic brake fluid Pack 0.5 litre CITROEN reference 9979 05 9979 06 9979 07 CITROEN reference GLYSANTIN G 33 9979 70 9979 71 9979 76 9979 77 REVCOGEL 2000 9979 72 9979 73 9979 74 9979 75

All countries

Protection : - 35C

GENERAL All countries CITROEN Fluid All countries TOTAL LHM PLUS TOTAL FLUIDE LDS

1 litre 5litres CITROEN hydraulic circuit fluid Norm ISO 7308-7309 Green in colour Orange in colour 28 Pack 1 litre

CITROEN reference ZCP 830 095 9979.20 (Scandinavia) 9979.69

LUBRICANTS - TOTAL recommended oils


WARNING: TOTAL LDS fluid cannot be blended with TOTAL LHM PLUS. All countries WARNING: CITRON C5 : Use only TOTAL FLUIDE LDS suspension fluid. Hydraulic circuit rinsing fluid- green in colour All countries TOTAL HYDRAURINCAGE Wash/wipe fluid Packs All countries Concentrated : 250 ml Liquid ready to use: 1 litre Liquid ready to use: 5 litres 9980 33 9980 06 9980 05 Grease Norms NLGI (1) All countries TOTAL MULTIS EP2 TOTAL MULTIS COMPLEX EP2 TOTAL MULTIS N4128 TOTAL SMALL MECHANISMS (1) NLGI = National Lubricating Grease Institute. 29 2 2 1 CITROEN reference ZC 9875 953 U ZC 9875 784 U ZC 9885 077 U

ALL TYPES

9980 56

ZC 9875 279 U

GENERAL

ALL TYPES
I - Oil consumption depends on : - the engine type. - how run-in or worn it is. - the type of oil used. - the driving conditions. II - An engine can be considered RUN-IN after: GENERAL - 3,000 miles (5,000 km) for a PETROL engine. - 6,000 miles (10,000 km) for a DIESEL engine.

ENGINE OIL CONSUMPTION

III - MAXIMUM PERMISSIBLE oil consumption for a RUN-IN engine. - 0.5 litres per 600 miles (1,000 km) for a PETROL engine - 1 litre per 600 miles (1,000 km) for a DIESEL engine. DO NOT WORK BELOW THESE VALUES. IV - OIL LEVEL : The level should NEVER be above the MAX. mark on the dipstick after changing or topping up the oil. - This excess oil will be used up rapidly. - It will reduce the engine output and adversely affect the operation of the air circuits and gas recycling.

30

ENGINE SPECIFICATIONS
Engines : 6FZ - RFN - RLZ - XFX Petrol

ALL TYPES

1.8i 16V

2.0i 16V

2.0 HPi

3.0i-V6

Engine type Cubic capacity (cc) Bore / Stroke Compression ratio Power ISO or EEC KW - rpm Power DIN (HP - rpm) Torque ISO or EEC (m.daN - rpm)

6FZ 1749 82.7/81.4 10.8/1 85-5500 117-5500 16-4000

RFN 1997 85/88

RLZ

XFZ 2946 87/82.6

11.4/1 100-6000 136-6000 19-4600 103-6000 143-6000 19.2-4100

10.9/1 152-6000 210-6000 28.5-3750

31

ENGINE

ENGINE

ALL TYPES

ENGINE SPECIFICATIONS
Engines : RHS - RHZ - RHY - RHW - 4HX Diesel

2.0 HDi

2.0 HDi 16V

2.2 HDi

Engine type Cubic capacity (cc) Bore / Stroke Compression ratio Power ISO or EEC KW - rpm Power DIN (HP - rpm) Torque ISO or EEC (m.daN - rpm)

RHS

RHZ 1997 85/88 17.6/1

RHY

RHW

4HX 2179 85/96 18/1

79-4000 107-4000 25-1750

80-4000 110-4000

66-4000 90-4000 20.5-1750

80-4000 110-4000 27-1750

98-4000 13.6-4000 31.7-2000

32

COMPRESSION RATIO - DIESEL ENGINES

ALL TYPES

ENGINE

COMPRESSION RATIO In bars

MAX. SPACING BETWEEN CYLINDERS

RHY RHS RHZ RHW 4HX DW12 20 5 DW10 30 5 5

33

ENGINE

ENGINE

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)


Engines : 6FZ - RFN - RLZ - RHY - RHS - RHZ - 4HX
Crankshaft 6FZ Petrol RFN RLZ RHY RHS Diesel RHZ 4HX

Bearing cap screws. - Pre-tightening - Angular tightening Con-rod cap screws. - Tightening - Slackening - Tightening - Angular tightening Con-rod nuts. - Pre-tightening - Angular tightening Accessories drive pulley - Tightening - Angular tightening Accessories drive pulley hub - Pre-tightening - Angular tightening (Sintered washer) - Angular tightening (Steel washer)

2 0.1 60 6

2.5 0.2 60

2.3 0.2 46 + 2 - 4 2 0.2 70 2.1 0.1 4 0.4 51

1 180 2.3 0.1 46 5

7 0.25 60

4 0.4 40 4 53 5

34

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)


Engines : 6FZ - RFN - RLZ - RHY - RHS - RHZ - 4HX
Cylinder block 6FZ Petrol RFN RLZ RHY RHS Diesel RHZ 4HX

Piston skirt spray jet Sump - Pre-tightening - Tightening Timing belt guide roller - Pre-tightening - Tightening Timing guide roller - Pre-tightening - Tightening Timing belt tensioner roller RH engine mounting - Pre-tightening - Tightening - Tightening 2.1 0.2 2.5 0.2 3.7 0.3 2.5 0.2 0.8 0.2 1.6 0.2

1 0.1

1 1.6 0.3

1.5 4.3 0.4

1.5 4.3 0.4

2.5 0.2
1 (4 screws) 2 0.2 ( 8) 4.50.2 (10)

6.1 0.6

2.7 0.2

35

ENGINE

ENGINE
Valve cover - Pre-tightening - Tightening Hub pulley Flywheel - Pre-tightening - Tightening Clutch plate

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)


Engines : 6FZ - RFN - RLZ - RHY - RHS - RHZ - 4HX
Cylinder head 6FZ Petrol RFN RLZ RHY RHS Diesel RHZ 4HX

Camshaft bearing cover - Tightening - Pre-tightening - Tightening Exhaust manifold - Pre-tightening - Tightening

0.5 0.1 0.9 0.1

1 0.1

1 0.1 0.5 (6) 10.1(10) 1.5 3 0.3

3.5 0.3 0.5 1.1 0.1 7.5 0.7

2 0.2

0.9 0.1

0.8 0.1 4.3 0.5 2 0.2

0.5 0.15 0.9 0.1

Camshaft pulley hub

Flywheel / Clutch 2 0.2 21 3 2 0.2


1.5 4.7 0.4

4.8 0.5 2 0.2

36

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)


Engines : 6FZ - RFN - RLZ - RHY - RHZ - 4HX Lubrication circuit 6FZ
Oil pump - Pre-tightening - Tightening Coolant / oil heat exhanger Lubrication pipe - Engine end - Turbocompressor end Injection circuit Injector - Tightening - Angular tightening Union on injection rail Injection pump Union on injector Common rail fixing screw Injection pump pulley Union on injection pump Cooling circuit Coolant pump Coolant inlet housing

Petrol RFN RLZ RHY RHS

Diesel RHZ 4HX


0.7 0.9 0.1

0.9 0.1

1.3 0.1 5.8 0.5 3 0.3 2 0.2 (Flange nut) 3 0.3 2 0.2 2.25 0.3 2 0.2 5 0.5 2 .02

0.4 0.03 45 5

0.5 0.1 0.9 0.1 0.8 0.1 2.6 0.3 1.4 0.1 0.9 0.1

1.6 0.3 2 .02

37

ENGINE

ENGINE

C5 - All Types

CYLINDER HEAD
Engines : 6FZ - RFN - RLZ Cylinder head gasket identification

Nominal dimension 6FZ Marking zone "d" Marking zone "e" Gasket thickness (mm) Supplier 0.8 MEILLOR 4-5 RFN - RLZ 1-4

Repair dimension

2-4-5 R1 R2

1.1

1.4

Multilayer metallic cylinder head gasket.

(d) Marking zone (e) Marking zone


B1DP183D

38

CYLINDER HEAD
Engines : 6FZ - RFN - RLZ Cylinder head tightening (m.daN) 6FZ - RFN - RLZ Pre-tightening Tightening Slackening Tightening Angular tightening 1.5 0.1 5 0.1 360 2 2 0.2 285 5 Cylinder head bolts

(in the order 1 to 10)

B1DP16FC

NOTE : Retightening of the cylinder head after a completed repair is prohibited.Intervention est interdit.
B1DP05BC

NOTE: Oil the threads and under the heads of the cylinder head bolts. (Use engine oil or Molykote G Rapid Plus.)

A = Washer thickness : 4 0.2 mm. X = Length under heads of the new bolts = 144.5 0.5 mm. X = MAX. re-usable length 6FZ - RFN - RLZ X= 147 mm

39

ENGINE

ENGINE
B1BP1HAP

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)


Engine : XFZ

(1) Compact coil unit (9) Flywheel - Tightening - Angular tightening (11) Connecting rod caps - Tightening - Angular tightening (12) Crankshaft hub - Tightening - Angular tightening (13) Crankshaft pulley

1 0.1

1 60 6

2 74 7

4 0.4 80 8 2.5 0.2

40

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)


Engine : XFZ - 2 Cylinder head cover (A) Front cyl. head - (B) Rear cyl. head - 3 Bearing caps housing (A) Front cyl. head - (B) Rear cyl. head

B1DP08UD

B1DP08TD

WARNING : Tighten screw by screw in the order shown. - Pre-tighten : - Tighten : 0.5 1 0.1 41 - Pre-tighten : - Tighten : 0.2 0.8

ENGINE

ENGINE
B1HPOLJC

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)


Engine : XFZ - 5 Air inlet manifold - 6 Lower manifold (A) Front cyl. head - (B) Rear cyl. head

B1DP097C

WARNING : Tighten screw by screw in the order shown. - Pre-tighten : - Tighten : 1 0.1 2 0.2 42 - Pre-tighten : - Tighten : 1 0.1 2.5 0.2

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)


Engine : XFZ - 7 Exhaust manifold (NEW seal) - 10 Oil sump

B1BP1GXD

B1BP1GZD

WARNING : Tighten screw by screw in the order shown. - Pre-tighten : - Tighten : 1 0.1 3 0.3 43 - Pre-tighten : - Tighten : 0.5 0.8

ENGINE

ENGINE
B1BP1GYD

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)


Engine : XFZ - 8 Crankshaft bearing

- Clean the threads of the screws with a brush. - Refit the screws with a coating of grease ( MOLYKOTE G RAPID PLUS ). - Check that the 8 centring pins are in place. Maximum length under the heads of the screws : - M11 = 131.5 mm. - M8 = 119 mm. - Pre-tighten the M11 screws to 3 m.daN 0.3 (1 to 8 ). - Pre-tighten the M8 screws to 1 m.daN 0.1 (A to H). - Tighten the M6 screws to 1 m.daN 0.1 (a to m). - Slacken the M11 and M8 screws (screw by screw). - Tighten the M11 screws to 3 m.daN 0.3 (1 to 8). - Tighten the M8 screws to 1 m.daN 0.1 (A to H).

44

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)


Engine : XFZ

(14) Water pump - Pre-tighten - Tighten (15) Oil pump - Pre-tighten - Tighten (16) Guide roller (17) Tensioner roller (18) Camshaft hubs - Pre-tighten - Tighten (19) Camshaft pulley
B1BP1HBD

0.5 0.8

0.5 0.8 8 0.8 8 0.8

2 0.2 57 5 1 0.1

45

ENGINE

ENGINE
B1BP1H1D

SPECIAL FEATURES : TIGHTENING TORQUES (m.daN)


Engine : XFZ - 20 Oil vapour recovery housing.

WARNING : Tighten screw by screw in the order shown. - Pre-tighten - Tighten 0.5 1 0.1

46

CYLINDER HEAD
Engine : XFZ Cylinder head gasket identification Supplier Thickness (Standard) (mm) 0.75 Thickness reference Central lug Exhaust end

ERLING

Multilayer metallic cylinder head seal. 47

(1) LH cylinder head gasket. (2) RH cylinder head gasket.

B1DP18YD

ENGINE

ENGINE

CYLINDER HEAD
Engine : XFX Cylinder head tightening (m.daN) Cylinder head bolts

In the order indicated. - Pre-tightening - Slackening - Pre-tightening - Angular tightening 2 0.2 YES 1.5 0.2 225

Note : Oil the threads and under the heads of the bolts. (Use engine oil or Molykote G Rapid Plus). X = MAX. re-usable length XFX
B1DP18ZD B1DP09VC

149.5 mm

48

CYLINDER HEAD
Engines : RHY - RHS - RHZ Cylinder head gasket identification Engine plate Piston stand-proud (mm) 0.47 to 0.605 RHZ RHY 0.605 to 0.655 0.655 to 0.705 0.705 to 0.755 0.755 to 0.83 Thickness (mm) 1.30 0.06 1.35 0.06 1.40 0.06 1.45 0.06 1.50 0.06 Number of notches at A 1 2 3 4 5

B1DP15AD

49

ENGINE

ENGINE
B1DP05BC

CYLINDER HEAD
Engines : RHY - RHS - RHZ Cylinder head gasket identification Cylinder head tightening (m.daN) RHY - RHS - RHZ - Pre-tightening - Tightening - Angular tightening 2 6 220 Cylinder head bolts RHY - RHS - RHZ

NOTE : Oil the threads and under the heads of the bolts. (Use engine oil or Molykote G Rapid Plus). X = MAX. re-usable length RHY - RHS - RHZ 133.3 mm 50

B1DP15EC

CYLINDER HEAD
Engine : 4HX Cylinder head gasket identification Number of notches Engine plate Piston stand-proud (mm) 0.55 to 0.60 4HX 0.61 to 0.65 0.66 to 0.70 0.71 to 0.75 Thickness (mm) 1.25 0.04 1.30 0.04 1.35 0.04 1.40 0.04 1

At A

At B 1 2 3 4

Cylinder head gasket. Multilayer cylinder head gasket. Select seal thickness as a function of the piston stand-proud.

B1DP18XD

51

ENGINE

ENGINE
B1DP05BC

CYLINDER HEAD (continued)


Engine : 4HX Cylinder head tightening (m.daN) 4HX ESSENTIAL : Tighten screw by screw and in the order indicated. Cylinder head bolts 4HX

- Pre-tightening - Tightening - Slackening - Pre-tightening - Tightening - Angular tightening (in 2 attempts max.)

2 0.2 (Order 6 0.6 (Order 360 (Order 2 0.2 (Order 6 0.6 (Order 220 5 (Order

1 to 10) 1 to 10) 10 to 1) 1 to10) 1 to10) 1 to10) NOTE : Oil the threads and under the heads of the bolts. (Use engine oil or Molykote G Rapid Plus). X = MAX. re-usable length 4HX X = 134.5 MM

B1DP15EC

52

BELT TENSION/SEEM UNITS CORRESPONDENCE TABLE !


4099-T (C.TRONIC.105)

B1EP135D

53

Tooling

ALL TYPES 4122-T (C.TRONIC.105.5) !

ENGINE

ENGINE

C5 - SYNERGIE
EW 7 J4 Engine type C5 SYNERGIE See pages : 6FZ X RFN X X 56 10 D RLZ X

AUXILIARY EQUIPMENT DRIVE BELT


ES 9 J4 XFX X TD RHY X RHS X 10 ATED RHZ X X 57 58 to 61 X 62 to 63 ATED4 RHW DW 12 TED 4HX X

54

AUXILIARY EQUIPMENT DRIVE BELT


Engines : All Types Petrol and Diesel

ALL TYPES

TOOLS - Belt tension measuring instrument : 4122 - T. (C.TRONIC 105.5) - WARNING : If using tool 4099-T (C.TRONIC 105) refer to the correspondence table on page 53.

ESSENTIAL - Before refitting the auxiliary equipment drive belt, check that : 1) The roller(s) rotate freely (no play or stiffness) 2) The belt is correctly engaged in the grooves of the various pulleys.

55

ENGINE

ENGINE

SYNERGIE
Without aircon

AUXILIARY EQUIPMENT DRIVE BELT


Engines : 6FZ - RFN - RLZ Tools [1] Pliers for removing plastic pegs Remove the belt. - Detension the belt (3) by turning the tensioner roller (1), by the screw (2) (anti-clockwise). WARNING : the screw (2) has a left hand thread. - Remove the belt (3), while keeping the tensioner roller (1) tensioned. Refit the belt. - Compress the tensioner roller (1). - Fit the belt (3). - Release the tensioner roller (1). Tightening torques m.daN. Tensioner roller screw (4) Guide roller screw (5)
B1BP23PC B1BP23QC

With aircon

7504-T

2 0.2 3.5 0.3


B1BP23PC B1BP23RC

56

AUXILIARY EQUIPMENT DRIVE BELT


Engine : XFX Tools [1] Ratchet spanner S.171 FACOM (1/2 square) [2] Reduction box S.230 FACOM (1/2-3/8) S 171. S 230.

C5 - All Types

Remove. Remove the engine cover. Pivot the tensioner roller bracket (1) clockwise, until it locks, using tools [1] and [2] at a. Remove the auxiliary equipment drive belt. ESSENTIAL : Check that the guide rollers are turning freely. (No play and no tightness). Refit. Refit the auxiliary equipment drive belt: Respect the following order of assembly : - The crankshaft pulley (2). - The tensioner roller (3). Release the tensioner roller bracket (1), by turning it anti-clockwise, using tools [1] and [2]. ESSENTIAL : Make sure that the belt is correctly positioned in the grooves of the various pulleys. 57

B1BP27EC

B1BP27FC

ENGINE

ENGINE

SYNERGIE

AUXILIARY EQUIPMENT DRIVE BELT


Engines : RHY - RHS - RHZ Without air conditioning Tools [1] [2] [3] [4] Belt tension adjusting square 4 mm peg 2 mm peg Dynamic tensioner compression lever : (-).0188 J2 : (-).0188.Q1 : (-).0188.Q2 : (-).0188.Z

Remove Re-use of belt WARNING : Mark the direction the belt was fitted in case of re-use of the same belt. - Compress the tensioner roller (2) by action at a (in anti-clockwise direction), tool [4]. - Keep the tensioner roller (2) compressed and remove the belt. No re-use of belt. - Compress the dynamic tensioner roller (2) by action at a (anti-clockwise), using tool [4]. - Peg using tool [2], at b . - Hold the dynamic tensioner roller (2) compressed and remove the belt. - Loosen the screw (1).
B1BP1YKD

58

AUXILIARY EQUIPMENT DRIVE BELT


Engines : RHY - RHZ Without air conditioning (continued) Refit. Re-used belt.

SYNERGIE

- Compress the tensioner roller (2) by action at a (anti-clockwise), tool [4]. - Refit the belt. WARNING : Respect the direction in which the belt is fitted. - Remove the tool [4]. New belt. Refit the belt. - Turn the eccentric roller (3), tool [1] (clockwise) to free the tool [2] from its pegging at b . - Hold the eccentric roller (3), tool [1], and tighten the screw (1) to 4.3 0.5 m.daN. Remove the tool [2]. - Rotate the crankshaft 4 times in the direction of rotation. - Check that it is possible to peg at b , tool [3]. - If not possible to peg, restart the adjustment.
B1BP1YMD

59

ENGINE

ENGINE

SYNERGIE

AUXILIARY EQUIPMENT DRIVE BELT


Engines : RHY - RHZ With air conditioning [1] [2] [3] [4] Tools Belt tension adjusting square 4 mm peg 2 mm peg Dynamic tensioner compression lever : : : : (-).0188 J2 (-).0188.Q1 (-).0188.Q2 (-).0188.Z

Remove Re-use of belt WARNING : Mark the direction the belt was fitted in case of re-use of the same belt. - Compress the tensioner roller (7) by moving it at c (in anti-clockwise direction), tool [4]. - Hold the tensioner roller (7) compressed and remove the belt. No re-use of belt. - Compress the tensioner roller (7) by moving it at c (in anti-clockwise direction), tool [4]. - Peg using tool [2], at d . - Loosen the screw (6). - Bring the eccentric roller (5) towards the rear. - Tighten the screw (6) by hand. - Remove the belt.
B1BP1YLD

60

AUXILIARY EQUIPMENT DRIVE BELT


Engines : RHY - RHZ With air conditioning (continued) Refit.

SYNERGIE

Re-used belt. - Compress the tensioner roller (7) by action at c (in anti-clockwise direction), tool [4]. - Refit the belt. WARNING : Respect the direction in which the belt is fitted. - Remove the tool [4]. New belt. Refit the belt. - Turn the eccentric roller (5), tool [1] (clockwise) to free the tool [2] from its pegging at d . - Hold the eccentric roller (5), tool [1], and tighten the screw (6) to 4.3 0.5 m.daN. - Remove the tool [2]. - Rotate the crankshaft 4 times in the normal direction of rotation. - Check that it is possible to peg at d , tool [3]. - If not possible to peg, restart the adjustment.

B1BP1YND

61

ENGINE

ENGINE

C5 - All Types

AUXILIARY EQUIPMENT DRIVE BELT


Engine : 4HX Without air conditioning TOOLS [1] Dynamic tensioner compression lever [2] Peg 4 mm Remove. WARNING : mark the direction of fitting in case the belt is to be reused. - Compress the tensioner roller (1) by action at a (anti-clockwise), using tool [1]. - Peg at b, using tool [2]. - Remove the auxiliaries drive belt. Refit. - Refit the auxiliaries drive belt. - Compress the tensioner roller (1) by action at a (anti-clockwise), using tool [1]. - Remove the tool [2] at b. : (-).0188.Z : (-).0188.Q1

B1BP270D

B1BP272D

62

AUXILIARY EQUIPMENT DRIVE BELT


Engine : 4HX With air conditioning TOOLS [1] Dynamic tensioner compression lever [2] Peg 4 mm Remove. WARNING : mark the direction of fitting in case the belt is to be reused.

C5 - All Types

: (-).0188.Z : (-).0188.Q1

- Compress the tensioner roller (4) by action at c (anti-clockwise), using tool [1]. - Peg at d, using tool [2]. - Remove the auxiliaries drive belt. Refit. - Refit the auxiliaries drive belt. - Compress the tensioner roller (4) by action at c (anti-clockwise), using tool [1]. - Remove the tool [2] at d.

B1BP271D

B1BP273D

63

ENGINE

ENGINE

C5 - All Types
EW 7 J4 Engine type C5 SYNERGIE See pages : 6FZ X RFN X X 65 to 68 10

CHECKING AND SETTING THE VALVE TIMING


ES 9 D RLZ X J4 XFX X TD RHY X RHS X 10 ATED RHZ X X 69 to 74 75 to 79 X 80 to 85 ATED4 RHW DW 12 TED 4HX X

64

CHECKING AND SETTING THE VALVE TIMING


Engines : 6FZ - RFN - RLZ TOOLS [1] Camshaft setting pegs : (-).0189.A [2] Crankshaft setting peg : (-).0189.B Toolkit C.0189. [3] Belt retaining pin : (-).0189.K [4] Adaptor for angular tightening : 4069-T [5] Hub immobilising tool : 6310-T Checking the valve timing. - Turn the engine by the crankshaft pinion screw (1) to bring it to pegging position. - Peg the crankshaft, using tool [2]. - Peg the camshaft pulleys, using tools [1]. NOTE : The pegs [1] should engage without effort. WARNING : if the pegs do not engage without effort, restart the fitting and tensioning of the timing belt (see below). Setting the valve timing. Remove. - Remove the screws (2), the pulley (1), upper valve cover (4), lower valve cover (3). - Turn the engine by the screw (13) of the pinion (12) to bring it to pegging position. - Peg the pulleys (8) and (9) using tools [1]. - Peg the pinion (12) using tool [2]. - Loosen the screw (7) of the tensioner roller (6). - Turn the tensioner roller (6) (clockwise). - Remove the timing belt (10). 65

C5 - All Types

B1BP22SC B1BP25PC B1BP23XC B1EP14JD

ENGINE

ENGINE

C5 - All Types

CHECKING AND SETTING THE VALVE TIMING


Engines : 6FZ - RFN - RLZ Refit (continued) - Refit the belt (10) on the pinion (12). - Hold the belt (10) with tool [3]. - Position the belt (10) in the following order : - The guide roller (11), the inlet camshaft pinion (9), the exhaust camshaft pinion (8), the water pump (5), the tensioner roller (6). NOTE : Make sure that the belt (10) is as flush as possilble with the outer face of the various pinions and rollers. - Remove the tools [3] and [1]. Timing belt. Adjusting the tension. - Turn the roller (6) in the direction of the arrow b; using an Allen key at a. -Position the index c in its maximum setting at d. IMPERATIVE : The index c must stand proud of the notch f by an angular value of 10. If it does not, replace the tensioner roller (6) or the timing belt and the tensioner roller (6) Bring the index c to its adjusting position f by turning the tensioner roller (6) in the direction of the arrow e WARNING: The index c must not stand proud of the notch f : if it does, restart the timing belt tensioning operation. IMPERATIVE : The tensioner roller (6) must not turn while its fixing is being tightened up. If it does, recommence the adjusting operation.
B1EP14JD B1EP14KC

66

CHECKING AND SETTING THE VALVE TIMING


Engines : 6FZ - RFN - RLZ Adjusting the tension (continued). -Tighten the screw (7) of the the tensioner roller (6) to 2.1 0.2 m.daN.

C5 - All Types

IMPERATIVE : The hexagonal drive of the tensioner roller (6) must be at 15 below the level of the cylinder head gasket g. If not, replace the tensioner roller (6) or the timing belt and the tensioner roller (6). Refit (continued). - Remove the tools [1] and [2]. -Turn the crankshaft 10 times in the normal direction of rotation. IMPERATIVE : No pressure or outside action must be brought to bear on the timing belt. - Peg the inlet camshaft pulley, using the tool [1]. Checks. Timing belt tension. IMPERATIVE : Check the position of the index c, it should be facing the notch f. If the position of index c is not correct, restart the adjustment of its position. Positioning of the crankshaft. - Fit tool [2]. - As long as it is possible to fit tool [2], continue with the refit operations. IMPERATIVE : If it is not possible to fit tool [2], reposition the flange (14).
B1EP14MC B1EP14VC

67

ENGINE

ENGINE

C5 - All Types

CHECKING AND SETTING THE VALVE TIMING


Engines : 6FZ - RFN - RLZ Checks (continued) Repositioning the flange. -Immobilise the crankshaft using tool [5]. -Loosen the screw (13). -Release the pinion (12) of the crankshaft. -Bring the flange (14) to the pegging position; using tool [5]. -Fit the tool [2]. -Immobilise the crankshaft using tool [5]. -Tighten screw (13) to 4 0.4 m.daN, then angular tighten to : 53 4 (Assembly with steel washer, gold in colour) 40 4 (Assembly with sintered washer, metallic in colour) using the tool [4]. Remove tools [1]. [2] and [5]. Refit : - The lower valve cover (3). -The upper valve cover (4). -The crankshaft pulley (1). -The screws (2). -Pretighten the screws (2) to 1.5 m.daN. -Tighten the screws (2) to 2.1 0.5 m.daN.
B1EP14PC B1EP14JD B1BP23XC

68

CHECKING AND SETTING THE VALVE TIMING


Engine : XFX OUTILLAGES [1] [2] [3] [4] [5] [6] Camshaft setting pegs Crankshaft setting peg Fuel pressure take-off union Belt retaining pin Exhaust camshaft hubs immobilising tool Inlet camshaft hubs immobilising tool

C5 - All Types

(-).0187.B (-).0187.A 4192-T (-).0187.J (-).0187.F (-).0187.F

Remove the auxiliaries drive belt (See corresponding operation). Checking the valve timing setting. Remove : - The power steering pulley. - The roller / dynamic tensioner assembly (11). - The crankshaft pulley (12). - The upper timing covers (9) and (10). - The lower timing cover (13).
B1BP2BKC

69

ENGINE

ENGINE

C5 - All Types

CHECKING AND SETTING THE VALVE TIMING


Engine : XFX Checking the valve timing setting (continued). - Peg the crankshaft, using tool [1]. - Check that the tool [2] engages without effort in the cylinder heads at the camshaft pulleys. - Remove the tools [1] and [2].

Refit : - The - The - The - The - The lower timing cover (13). upper timing covers (9) and (10). crankshaft pulley (12). roller / dynamic tensioner assembly (11). power steering pulley.

- Complete the refitting of components. - Initialise the ignition injection ECU.

B1EP08TC

B1EP15UD

70

CHECKING AND SETTING THE VALVE TIMING


Engine : XFX Setting the valve timing - Remove the components as necessary for the operation. - Remove the screws (19) and the plate (20). - Peg the crankshaft, using tool [2].

C5 - All Types

NOTE : Damp the rotation of the camshafts (15) and (17), using tool [6]. - Untighten the camshaft pulley screws (15) and (17). NOTE : Damp the rotation of the camshafts (14) and (18), using tool [5]. - Untighten the camshaft pulley screws (14) and (18). NOTE : Lubricate the tools [1], with grease G6 (TOTAL MULTIS). Peg the camshafts, using tools [1], [5] and [6]. Remove the screw (21) of the panel (25). Untighten the nut (23) of the tensioner roller (24). Untighten the screws (22) of the panel (25). Remove the guide roller (16). WARNING : mark the direction of fitting of the timing belt, in case the belt is to be reused - Remove the timing belt.
B1EP15VD

71

ENGINE

ENGINE

C5 - All Types

CHECKING AND SETTING THE VALVE TIMING


Engine : XFX Setting the valve timing (continued) Refit. - Check that the camshafts and the crankshaft are correctly pegged. - Check that the rollers and the water pump pulley are turning freely. (No tightness). - Loosen the camshaft pulley screws by a 1/4 turn. - Make sure that the pulleys are turning freely on the camshaft hub. - Turn the camshaft pulleys in a clockwise direction, to end of slots. WARNING : Respect the direction of fitting of the belt : facing the timing, the inscriptions on the belt should be readable the correct way up. - Fit the timing belt on the crankshaft pinion. - Position the tool [6]. - Position the timing belt in the following sequence : (Belt well tensioned). - The roller (26), the pulley (18), the pulley (17), - Keep the timing belt well tensioned : - Refit the guide roller (16), tighten to 8 0,8 m.daN. - Position the timing in the following sequence : - The camshaft pulley (15), the camshaft pulley (14), the tensioner roller (24), the water pump pulley, and the guide roller (27). NOTE : When positioning the belt on the camshaft pulleys, turn these clockwise so as to engage the next tooth. The angular displacement of the pulleys should not be more than the equivalent of one tooth.
B1EP15VD

B1BP2BLC

72

CHECKING AND SETTING THE VALVE TIMING


Engine : XFX Setting the valve timing (continued) Adjusting the timing belt tension.

C5 - All Types

- Pivot the plate (25) of the tensioner roller (24), using a spanner. (type FACOM S.161). - Engage the screw (21) on the plate (25). - Tighten the screws (21) and (22), tighten to 2,5 0,1 m.daN. - Position the belt under maximum tension ; pivot the tensioner roller (24),using a spanner (type FACOM R 161). - Tighten the nut (23) of the tensioner roller (24), tighten to 1 0,1 m.dan. - Check that the camshaft pinion screws are not at the end of slots. (By loosening one screw). - Otherwise, restart the operation of positioning the timing belt. - Tighten at least 2 screws per camshaft pulley to 1 0,1 m.daN. - Remove the tools [1], [2] and [4]. - Rotate the crankshaft 2 turns in a clockwise direction. IMPERATIVE : Never turn it back. - Peg the crankshaft, using tool [2], and the camshaft pulleys, using tool [1]. - Untighten the nut (23) of the tensioner roller (24). - Adjust the belt tension, pivoting the roller (24) using tool (type FACOM S.161).
B1EP15WC B1EP15XC

73

ENGINE

ENGINE

C5 - All Types

CHECKING AND SETTING THE VALVE TIMING


Engine : XFX Setting the valve timing (continued) - Align the marks c and d, without detensioning the timing belt. (Failing this, restart the operation of adjusting the belt tension). - Hold the tensioner roller (24). - Tighten the nut (23), tighten to 1 0,1 m.daN. - Check the position of the tensioner roller. - Remove the tools [1], [2] and [4]. - Turn the crankshaft 2 rotations in the direction of engine rotation. IMPERATIVE : Never turn it back. - Peg the crankshaft, using tool [2]. - Check the roller position (24) (the alignment of the marks c and d should be correct) - Peg the camshaft pinions, using tool [1]. - If the peg [1] goes in, loosen the camshaft pulley screws by 45. - If the peg [1] does not go in, then loosen the camshaft pulley screws by 45 and manoeuvre the hub using tool [5] until pegging is achieved. WARNING : Check that the camshaft pinion pulleys are not at the end of slots. Otherwise, restart the operation of positioning the timing belt. - Tighten the camshaft pinion screws to 1 0,1 m.daN. - Remove the tools [1] and [2]. - Refit the panel (20), the screws (19) and tighten to 4 0, m.daN. - Complete the refitting of all components.

B1EP15XC

74

CHECKING AND SETTING THE VALVE TIMING


Engines : RHY - RHS - RHZ [1] [2] [3] [4] [5] [6] [7] [8] Tools Belt tension measuring instrument : 4122-T Tension lever : (-).188.J2 Engine flywheel peg : (-).188.X Belt retaining pin : (-).0188.K Camshaft pinion peg : (-).0188.M Engine flywheel lock : (-).0188.F Set of blocking plugs : (-).0188.T Crankshaft pulley extractor : (-).0188.P Checking the setting of the valve timing. Peg : - The engine flywheel, using tool [3]. (From under the vehicle). - The camshaft, using tool [5]. WARNING : On removing screws (6), (7), (9), and (5) of the timing cover, refit the screw (5) equipped with a spacer (thickness: 17 mm) Tighten to 1,5 0,1 m.daN. (The screw (5) is one of the screws fixing and sealing the water pump). WARNING : Should it be impossible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm, with the help of a mirror a and a 7 mm screw. IMPERATIVE : If pegging is impossible, restart the adjusting. (See corresponding operation).
B1EP14AC B1BP282C B1EP152D B1BP1YSC

C5 - All Types

75

ENGINE

ENGINE

C5 - All Types

CHECKING AND SETTING THE VALVE TIMING


Engines : RHY-RHS-RHZ Setting the valve timing. Peg : - The engine flywheel, tool [3]. (From under the vehicle) - The camshaft, tool [5]. Loosen : - The three screws (9). - The screw (7) of the tensioner roller (6). - Remove the timing belt. Checks. IMPERATIVE : Just before refitting, carry out the checks below: Check that : - The rollers (20), (23) and the water pump turn freely (without play or tightness). - There are no traces of oil (on camshaft or crankshaft). - There are no leaks of coolant fluid (from water pump). - Replace defective components (if necessary).
B1BP282C B1EP152D

76

CHECKING AND SETTING THE VALVE TIMING


Engines : RHY - RHS - RHZ Setting the valve timing (continued). Retighten the screws (21) by hand. Turn the pinion (24) (clockwise) to the bottom of the buttonhole. Refit the belt on the crankshaft (25). Hold the belt, using tool [4].

C5 - All Types

Reposition the timing belt, keeping the belt tight at a , in the following order : - Guide roller (23). - Fuel high pressure pump pinion (26). - Camshaft pinion (24). - Water pump pinion (18). - Tensioner roller (20). NOTE : If needed, slightly turn the pinion (24) anti-clockwise (not by more than one tooth). - Remove the tool [4].

B1EP153D

B1EP154C

B1EP155D

77

ENGINE

ENGINE

C5 - All Types

CHECKING AND SETTING THE VALVE TIMING


Engines : RHY - RHS - RHZ Setting the valve timing (continued). - Position tool [1] on the belt at b . - Turn the roller (20) (anti-clockwise) using tool [2] to attain a tension of : 98 2 SEEM units. - Tighten the screw of the roller (19), tighten to 2.5 m.daN. - Remove one screw (21) from the pinion (24). (to check that the screws are not against the end of the buttonhole). - Tighten the screws (21) to 2 m daN. - Remove tools [1], [2], [3] and [5]. - Rotate the crankshaft 8 times (normal direction of rotation). - Fit the tool [3]. - Loosen screws (21). - Fit tool [5]. - Loosen screw (19) (to free the roller. - Fit tool [1]. - Turn the roller (20) (anti-clockwise), tool [2], to attain a tension of : 54 2 SEEM units.

B1EP156D

78

CHECKING AND SETTING THE VALVE TIMING


Engines : RHY - RHS - RHZ Setting the valve timing (continued). Tighten : - The screw of the roller (19) to 2.5 0.2 m.daN. - The screws (21) to 2 0.2 m.daN. - Remove the tool [1]. - Refit the tool [1]. - Tension value should be : 54 3 SEEM units.

C5 - All Types

IMPERATIVE : If value is incorrect, restart the operation. - Remove tools [1], [3] and [5]. - Rotate the crankshaft 2 times (normal direction of rotation). - Fit the tool [3]. WARNING : Should it be impossible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm. In the case of an incorrect value, recommence the operation. - Remove the tool [3]. - Complete the refitting of components.
B1EP156D

79

ENGINE

ENGINE

C5 - All Types

CHECKING AND SETTING THE VALVE TIMING


Engine : 4HX Tools [1] Belt tension measuring instrument [2] Engine flywheel peg [3] Tension lever [4] Belt compression spring [5] Camshaft pinion peg [6] Engine flywheel lock [7] Set of blocking plugs : : : : : : : 4122-T (-).0188.X. (-).0188.Y. (-).0188.K. (-).0188.M. (-).0188.F. (-).0188.T.

IMPERATIVE : Respect the safety and cleanliness recommendations specific to high pressure diesel injection (HDi) engines. Checking the setting of the valve timing. - Turn the crankshaft (normal direction of rotation) and line up the black markings on the chain (b) and (c) with the teeth marked (a) and (d) of the camshaft drive pinions (40 turns max. of the camshaft).

B1EP159D

80

CHECKING AND SETTING THE VALVE TIMING


Engine : 4HX Checking the setting of the valve timing (continued).

C5 - All Types

IMPERATIVE : If it is impossible to line up the marks on the chain and on the camshaft drive pinions, restart the camshaft setting. (See operation for removing and refitting camshafts). - If the marks on the chains and pinions are coinciding, continue the checking operations. Peg : - The crankshaft, using tool [2]. - The camshaft pinion, using tool [5]. IMPERATIVE : Should it be impossible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm (use a screw 7 mm in dia.). If the offset is more than 1 mm, restart the setting of the valve timing (See corresponding operation). - Remove the tools [2] and [5].

B1BP298C B1EP15AD

81

ENGINE

ENGINE

C5 - All Types

CHECKING AND SETTING THE VALVE TIMING


Engine : 4HX Setting the valve timing. - Turn the crankshaft to bring camshaft to its pegging point. - Peg the crankshaft, using tool [3]. - Peg the camshaft, using tool [5]. Untighten : - The three screws (25). - The screw (23) of the tensioner roller (24). - Remove the timing belt (26). Checks. IMPERATIVE : just prior to refitting, carry out the checks below: Check : - That the rollers (24) and (27) and the water pump (22) are turning freely. (Without play and without tightness). - Absence of traces of oil leaks (Crankshaft and camshaft sealing rings). - Absence of leaks of coolant fluid (Water pump). NOTE : Replace defective components (If necessary).
B1BP298C B1EP15AD

82

CHECKING AND SETTING THE VALVE TIMING


Engine : 4HX Setting the valve timing (continued). Refit - Retighten the screws (25) by hand. - Turn the pinion (29) (clockwise) to the bottom of the buttonhole. - Refit the belt on the crankshaft (28). - Hold the belt, using tool [4]. Reposition the timing belt, keeping the belt tight at a, in the following order : - Guide roller (27). - Fuel high pressure pump pinion (30). - Camshaft pinion (29). - Water pump pinion (22). - Tensioner roller (24). NOTE : If needed, slightly turn the pinion (29) anti-clockwise (not by more than one tooth). - Remove the tool [4].

C5 - All Types

B1EP15BD B1EP15CC

B1EP15DD

83

ENGINE

ENGINE

C5 - All Types

CHECKING AND SETTING THE VALVE TIMING


Engine : 4HX Setting the valve timing (continued) - Position tool [1] on the belt at b . - Turn the tensioner roller (24) (anti-clockwise) using tool [2] to attain a tension of : 106 2 SEEM units. - Tighten screw (23) of the tensioner roller, tighten to 2.5 m.daN. - Remove one screw (25) from the pinion (29). (to check that the screws are not against the end of the buttonhole). - Tighten the screws (25) to 2 m daN. - Remove tools [1], [2], [3] and [5]. - Rotate the crankshaft 8 times (normal direction of rotation). - Fit the tool [3]. - Loosen screws (25). - Fit tool [5]. - Loosen screw (23) (to free the tensioner roller (24). - Fit tool [1]. - Turn the tensioner roller (24) (anti-clockwise),using tool [3], to attain a tension of : 51 3 SEEM units. - Tighten : - The screw (23) of the tensioner roller (24) to 2,5 0,2 m.daN. - The screws (25) to 2 0.2 m.daN.

B1EP15ED

84

CHECKING AND SETTING THE VALVE TIMING


Engine : 4HX Setting the valve timing (continued) - Remove the tool [1]. - Refit the tool [1]. - Tension value should be : 51 3 SEEM units. IMPERATIVE : If value is incorrect, restart the operation.

C5 - All Types

- Remove tools [1], [2] and [5]. - Rotate the crankshaft 2 times (normal direction of rotation). - Fit the tool [3]. IMPERATIVE : Should it be impossible to peg the camshaft, check that the offset between the camshaft pinion hole and the pegging hole is not more than 1 mm. In the case of an incorrect value, recommence the operation. - Remove the tool [2]. - Complete the refitting of components.

B1EP15ED

85

ENGINE

ENGINE

ALL TYPES
The valve clearances must be checked with the engine cold G Inlet Exhaust

VALVE CLEARANCES
POSSIBLE PROCEDURES For engines with 4 cylinders in a line (1-3-4-2 ) Rocking Rocking Adjust 4 2 1 3 G Exhaust Inlet Fully open (Exhaust) Valves fully Adjust open
1 3 4 2 3 G 4 G 2 G 1 G 4 2 1 3

All Types

Hydraulic adjustment

1G 3G 4G 2G

1 4G 3 2G 4 1G 2 3G

Engines without hydraulic adjustment : the clearance (J) should be checked opposite the cam.
B1DP13QC

86

CHECKING THE OIL PRESSURE


Tools Toolkit 4103 -T 1.8i 16V Engine type Temperature (C) Pressure (Bars) Rpm 1.5 1000 5 3000 1.5 1000 5 3000 6FZ 2.0i 16V RFN 90C 1.5 1000 5 3000 7 900 Petrol engines 2.0 HPi RLZ

C5 - All Types

3.0i V6 XFX

8 3000

Diesel engines 2.0 HDi Engine type Temperature (C) Pressure (Bars) Rpm 2 1000 4 2000 2 1000 RHY - RHS -RHZ 90 4 2000 2 1000 4 2000 2.2 HDi 4HX

ESSENTIAL : Respect the safety and cleanliness recommendations.

87

ENGINE

ENGINE

C5 - All Types

OIL FILTERS
To be read together with the petrol and diesel correspondence tables

6FZ PURFLUX LS 304 LS 880 X

RFN X

RLZ X

XFX

RHY X

RHS X

RHZ X

4HX X

(mm) Specifications LS 304 LS 880 76 86

Height (mm) 89 97

88

FILLING AND BLEEDING THE COOLING CIRCUIT


TOOLS [1] Filling cylinder [2] Adaptor for filling cylinder : 4520-T : 4222-T.

C5 - All Types

ESSENTIAL : Respect the safety and cleanliness recommendations. - The draining and refilling operations can be carried out by means of a WINNS coolant replacement apparatus or similar; it is essential to follow the instructions when using this apparatus. Filling and bleeding - Fit the cylinder adaptor [2] 4222-T and the filling cylinder [1] 4520 -T. - Use the coolant to ensure protection between - 15C and - 37C. - Slowly fill the system. NOTE : Keep the cylinder filled up (visible level). - Close each bleed screw as soon as the coolant flows without air bubbles. - Start the engine : Engine speed 1500 rpm. - Maintain this speed until the third cooling cycle (cooling fans have cut in and cut out). - Stop the engine and allow it to cool down. - Remove the filling cylinder [1] 4520-T and the adaptor [2] 4222-T. - Top up the system to the maximum mark, with the engine cold. - Refit the filler cap.
B1GP00AC E5AP1GNC

89

ENGINE

INJECTION

C5 - All Types
Vehicles Engine type Emission standard

IDLING - ANTIPOLLUTION
Make - Injection type Idling speed ( 50 rpm) Manual gearbox Auto. gearbox: N engaged % Content CO CO2

L4 1.8 i 16V 6FZ IF/L5 C5 2.0 i 16V 2.0 HPi 3.0 i V6 SYNERGIE 2.0 i 16V RFN RLZ XFZ RFN IF/L5 L4 IF/L5 IF L5 MAGNETTI MARELLI 48P SIEMENS SIRIUS 81 BOSCH ME 7.4.6. M. MARELLI 48P2 < 0.5 >9 SAGEM S2000 7000

900 900 650 800 600

< 0.5

>9

90

PETROL INJECTION
C5 1.8I 16V
Engine type Emission standard Make Injection type Fuel pressure (bars) Overspeed cut-off (rpm) Injection cut-in during deceleration (rpm) Injector resistive value (ohms) Engine coolant temperature sensor resistive value (ohms) Idling actuator or stepper motor resistive value (ohms) Air temperature sensor resistive value (ohms)

C5 - All Types
SYNERGIE 2.0 HPi RLZ L4 SIEMENS SIRIUS 81 5 3.0I 24S V6 XFX IF/L5 BOSCH ME 7.4.6. 3.5 6520 1100 2.0 i 16 V RFN IF L5 M. MARELLI 48P2 INJECTION

2.0I 16V R6F L4 - IF/L5 MAGNETTI MARELLI MM. 48P 3.5

6FZ L4 - IF/L5 SAGEM S2000 3.5

12.2 3 800 at 10C

14.5 2500 at 20 C

1.88 800 at 50C

16 230 at 90 C

Stepper motor : 53 3 800 at 10C 2500 at 20 C 91 800 at 50C 230 at 90 C

ALL TYPES

ANTI-POLLUTION TECHNICAL CHECKS (FRANCE)


All Types Petrol CO Corrected (In %) All Types Diesel (m -1)

Conditions : At idle, engine warm.

INJECTION

# 01/96
Less than 4.5 % for vehicles registered before 10/86. Less than 3.5 % for vehicles registered after 10/86. With catalytic converter Greater than 2.0i 89 M.Y. All Types 93 M.Y. CO less than 0.5 % at idle speed. CO less than 0.3 % at fast idle speed between 2500 and 3000 rpm (*) Lambda Probe value 0.97 to 1.03.

01/96

Atmospheric engine. Less than 2.5 m -1 Turbocharged engine. Less than 3.0 m -1

92

EMISSION STANDARDS
STANDARD E.E.C. PSA A-S RP Engines APPLICATIONS Vehicles Applicable Brussels directive 83/351 except special derogations for certain private vehicles cyl. > 2 litres NOTES

ALL TYPES
CHARACTERISTICS

Private vehicles : > 2 litres new cyl. < 2 litres existing cyl. < 2 litres ECE R 15.04 K K 15.04 15.04 Petrol Diesel Utility vehicles : All Types

06/89 06/92 12/92

Utility vehicle limits 10/89


imminent = private vehicle limits increased by 25 % For private vehicles and utility vehicles in major export Brussels directive 88/76 " Luxembourg Accords " Replaced by 89/458 + 91/441

With oxygen sensor, without catalytic converter

ECE R 15.05

W vp

15.05

Petrol

Private vehicles : > 2 litres new models existing models

01/10/88 01/10/89

93

INJECTION

ALL TYPES
STANDARD E.E.C. PSA A-S RP Engines

EMISSION STANDARDS
APPLICATIONS Vehicles Applicable Brussels directives 88/76 and 88/436 NOTES CHARACTERISTICS

INJECTION

Utility vehicle limits


ECE R 15.05 W vu 15.05 Petrol Diesel Utility vehicles : All Types new models existing models 01/10/88 01/10/89 10/94 private vehicle limits of Brussels directive 88/436 7 classes of limits by vehicle weight

US 83

US 83

Petrol Diesel

Private vehicles : certain non-EEC European countries certain Export countries

Current

Adoption of the U.S.

With oxygen sensor and catalytic converter for petrol vehicles

94

EMISSION STANDARDS
STANDARD E.E.C. PSA A-S RP Engines APPLICATIONS Vehicles Private vehicles : certain non-EEC European countries certain Export countries Private vehicles : certain Export countries Utility vehicles : certain non-EEC European countries certain Export countries Utility vehicles : certain non-EEC European countries certain Export countries Applicable NOTES

ALL TYPES
CHARACTERISTICS

US 87

US 87

Diesel

Current

Adoption of the U.S.


standard

With catalytic converter and EGR

US 93

Y2

US 93

Petrol Diesel

Current

Adoption of the U.S.


standard

US 84 LDT

X1

US 84

Petrol Diesel

Current

Adoption of the U.S. standard for light utility vehicles

US 87 LDT

X2

US 87

Petrol Diesel

Current

Adoption of the U.S.


standard for light utility vehicles

95

INJECTION

ALL TYPES
STANDARD E.E.C. PSA A-S RP Engines Vehicles

EMISSION STANDARDS
APPLICATIONS Applicable NOTES CHARACTERISTICS

US 90 LDT

X3

US 90

Petrol Diesel

Private vehicles : certain non-EEC Current European countries certain Export countries Private vehicles : < 1.4 litres new models existing models

INJECTION

Adoption of the U.S.


standard for light utility vehicles

EURO 1 ( EURO 93) L1 CEE 19.5 Petrol Diesel

07/92 01/07/93 31/12/94

Brussels directive 89/458

Possible alternative to emission


standard L from 1992 to 1994

EURO 1 ( EURO 93)

CEE 19.5

Petrol Diesel

Private vehicles : All Types new models existing models new models existing models

07/92 01/93 01/96 01/97

EU Brussels Directive 93/59 (91/441)

With oxygen sensor and catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles.

96

EMISSION STANDARDS
STANDARD E.E.C. PSA A-S RP Engines APPLICATIONS Vehicles Utility vehicles : < 3.5 tonnes new models EURO 1 W2 (EURO 93) CEE W2 Petrol Diesel existing models Class 1 : new models existing models Class 2/3 : new models existing models Private vehicles : < 6 seats and < 2.5 tonnes new models existing models Applicable NOTES

ALL TYPES
CHARACTERISTICS

01/10/93 01/10/94

Brussels directive 93/59

3 classes depending on
vehicle weight : Class 1 < 1250 kg Class 2 : 1250/1700 kg Class 3 > 1700 kg

With oxygen sensor and catalytic converter for petrol vehicles

01/97 10/97 01/98 10/98

EURO2 (EURO 96) L3 CEE 95 Petrol Diesel

01/96 01/97

Brussels directive 94/12

EURO 93 standard made


stricter

With oxygen sensor and reinforced catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles.

97

INJECTION

ALL TYPES
STANDARD E.E.C. PSA A-S RP Engines Vehicles Utility vehicles : < 3.5 tonnes Class 1 : new models existing models Class 2/3 : new models existing models

EMISSION STANDARDS
APPLICATIONS Applicable Brussels directive 96/69 NOTES CHARACTERISTICS

INJECTION

EURO 2 (EURO 96) W3 CEE 95

Petrol Diesel Gas

3 classes depending on
01/97 10/97 01/98 10/98 vehicle weight : Class 1 < 1250 kg Class 2 : 1250/1700 kg Class 2 : 1 700 kg

With oxygen sensor and reinforced catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles.

EURO 3 L4 (EURO 2000)

Petrol CEE 2000 Diesel Gas

Private vehicles : All Types nouveaux modles modles existants

01/2000 01/2001

Brussels directive 98/69 EURO 2 standard (L3) made stricter Fiscal incentives

With 2 oxygen sensors and catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles.With EOBD on-board diagnosis.

98

EMISSION STANDARDS
STANDARD E.E.C. PSA A-S RP Engines APPLICATIONS Vehicles Utility vehicles : < 3.5 tonnes Class 1 : new models existing models Class 2/3 : new models existing models Applicable Brussels directive 98/69 EURO 2 standard (L3 made stricter Fiscal incentives 3 classes depending on vehicle weight : Class 1 < 1305 kg Class 2 : 1305/1760 kg Class 2 : 1760 kg Brussels directive 98/69 EURO 3 standard (L4) ) NOTES

ALL TYPES
CHARACTERISTICS

EURO 3 W3 (EURO 2000)

Petrol Diesel Gas

01/2000 01/2001 01/2001 01/2002

With 2 oxygen sensors and catalytic converter for petrol vehicles. With catalytic converter and EGR for diesel vehicles. With EOBD on-board diagnosis.

Private vehicles : All Types EURO 4 IF/ L5 Petrol new models existing models

01/2001 01/2003

made stricter

With 2 oxygen sensors and catalytic converter for petrol vehicles. With EOBD on-board diagnosis.

Fiscal incentives

99

INJECTION

ALL TYPES
STANDARD E.E.C. PSA A-S RP Engines Vehicles Private vehicles : All types new models existing models

EMISSION STANDARDS
APPLICATIONS Applicable With 2 oxygen sensors and catalytic converter for petrol vehicles. With EOBD on-board diagnosis. NOTES CHARACTERISTICS

EURO 4

IF / L5

Petrol Diesel Gas

01/2005 01/2006

Brussels Directive: 2001/1 EURO 3 standard (L4) made stricter Fiscal incentives

INJECTION

EURO 4 IF / L5

Petrol Gas

Utility vehicles : < 3.5 tonnes Class 1 : new models existing models Class 2/3 : new models existing models

01/2005 01/2006 01/2006 01/2007

Brussels Directives: 99/102 et 2001/1 (Gas) EURO 3 standard (L4) made stricter Fiscal incentives 3 classes depending on vehicle weight : Class 1 < 1305 kg Class 2 : 1305/1760 kg Class 3 : 1760 kg

With 2 oxygen sensors and catalytic converter for petrol vehicles. With EOBD on-board diagnosis.

100

PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM


Engines : RHY - RHS - RHZ - 4HX Cleaning. - The use of high pressure cleaners is prohibited. - Do not use compressed air. Fuel supply circuit. - Required fuel : diesel.

C5 - All Types

Electric circuit. - Swapping injection ECUs between two vehicles will render it impossible to start either vehicle. - It is forbidden to supply a diesel injector with 12 volts. High pressure fuel pump. Do not separate the following components from the high pressure fuel pump (5) : - Sealing ring (b) (no replacement parts). - High pressure outlet connector (a) (will cause a malfunction). HDi = High pressure Diesel injection

B1HP19LC

101

INJECTION

C5 - All Types

PROHIBITED OPERATIONS: HDi DIRECT INJECTION SYSTEM


Engines : RHY - RHS - RHZ - 4HX

Diesel injectors. INJECTION


B1HP19NC

WARNING: Diesel and ultrasonic cleaners are prohibited.

Do not separate the following components from the diesel injector carrier (2) : - Diesel injector (e) (no replacement parts). - Electromagnetic element (c) (no replacement parts).

Do not alter the position of the nut (d) (malfunction). Do not separate the connector (f) from a diesel injector. It is forbidden to clean the carbon deposits from the diesel injector nozzle.

102

SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM


Engines : RHY - RHS - RHZ -4 HX

C5 - All Types

Safety requirements. IMPERATIVE : Take into account the very high pressures in the high pressure fuel circuit (1350 bars), and respect the requirements below : - No smoking in proximity to the high pressure circuit when work is being carried out. - Avoid working close to flame or sparks. Engine running : - Do not work on the high pressure fuel circuit. - Always stay clear of the trajectory of any possible jet of fuel, which could cause serious injuries. - Do not place your hand close to any leak in the high pressure fuel circuit. After the engine has stopped, wait 30 seconds before any intervention. NOTE : This waiting time is necessary in order to allow the high pressure fuel circuit to return to atmospheric pressure.

103

INJECTION

SAFETY REQUIREMENTS Preamble. All interventions on the injection system must be carried out to conform with the following requirements and regulations : - Competent health authorities. - Accident prevention. - Environmental protection. WARNING : Repairs must be carried out by specialised personnel informed of the safety requirements and of the precautions to be taken.

C5 - All Types

SAFETY REQUIREMENTS : HDi DIRECT INJECTION SYSTEM


Engines: RHY - RHS - RHZ - 4HX

CLEANLINESS REQUIREMENTS. Preliminary operations IMPERATIVE : The technician should wear clean overalls. Before working on the injection system, it may be necessary to clean the apertures of the following sensitive components : (refer to corresponding procedures). - Fuel filter. - High pressure fuel pump. - Third piston deactivator. - High pressure regulator. - High pressure sensor. - High pressure fuel injection common rail. - High pressure fuel pipes - Diesel injector carriers. IMPERATIVE : After dismantling, immediately block the apertures of the sensitive components with plugs, to avoid the entry of impurities. Work area. - The work area must be clean and free of clutter. - Components being worked on must be protected from dust contamination. INJECTION

104

CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT


Engines : RHY - RHS - RHZ [1] [2] [3] [4] Engines : RHY - RHS - RHZ - 4HX TOOLS 10 mm low pressure connector 8 mm low pressure connector Pressure gauge for testing boost pressure Prolongateur

C5 - All Types

Connect the tool [1] between the booster pump and the fuel filter (white mark at "a" on the fuel supply pipe). Connect the tool [2] downstream of the diesel injectors, between the high pressure fuel pump and the fuel filter (green mark at "b" on the fuel return pipe. Engine : 4HX WARNING : Any check of pressure downstream of the fuel filter is PROHIBITED. NOTE : To check the pressures while the vehicle is being driven, insert tool [4] between tool [3] and tools [1] et [2]. Checks on pressure : static. - Switch on ignition - For 3 seconds (normal functioning): - Fuel supply pressure shown by the pressure gauge [3] = 2.6 0.4 Bar. - Fuel return pressure shown by the pressure gauge [3] = 0.6 0.4 Bar.
B1BP20JD B1BP27BD

105

INJECTION

: : : :

4215-T. 4218 -T. 4073-T 4251-T.

Kit 4073-T

C5 - All Types

CHECKS : LOW PRESSURE FUEL SUPPLY CIRCUIT


Engines : RHY - RHS - RHZ - 4HX (continued)

Checks on pressure : dynamic. Engine running, at idle (normal functioning): - Fuel supply pressure shown by the pressure gauge [3] = 2 0.4 Bar. - Fuel return pressure shown by the pressure gauge [3] = 0.8 0.4 Bar. Abnormal functioning Fuel supply pressure Between 3.3 and 4 Bar More than 4 Bar More than 4 Bar Between 0.8 and 1.5 Bar Fuel return pressure 0.8 0.4 Bar Less than 0.8 Bar More than 0.8 Bar Less than 0.8 Bar Checks Check the condition of the diesel filter Check the low pressure regulator incorporated in the filter (locked shut) : replace. Check the fuel return circuit (pipe pinched or trapped.......). Check the fuel suppy circuit : - Booster pump (low pressure), piping.

INJECTION

Impossible to start the engine : Fuel supply pressure less than 0.8 Bar : - Check the low pressure regulator incorporated in the filter (locked open) - Check the high pressure pump distribution valve (locked shut) Check : The flow should be drop by drop Excessive fuel return

Check : diesel injector return flow. (Table below) Uncouple the diesel injector return pipe. Observe : Diesel injector functioning correctly Diesel injector locked shut.

106

AIR SUPPLY CIRCUIT SPECIFICATION


Engine : RHY

C5 - All Types

(2) Flowmeter (3) Water / recycled gas exchanger (4) EGR valve (5) Turbocharger (6) Air butterfly

SIEMENS VALEO PURFLUX KKK K03 MAGNETI MARELLI 48W7 Ref. 648

B1HP1A6D

107

INJECTION

(1) Air filter

PSA 7899

C5 - All Types

AIR SUPPLY CIRCUIT SPECIFICATION


Engines : RHS - RHZ

(7) Air / air heat exchanger INJECTION


B1HP1A7P

VALEO. KKK K03. PURFLUX. MAGNETI MARELLI 48W7 Ref. 648. PSA 7899. NIPPON DENSO.

(8) Turbocharger (9) EGR valve (10) Air butterfly

(11) Air filter (12) Turbocharging pressure sensor

108

AIR SUPPLY CIRCUIT SPECIFICATION


Engine : 4HX

C5 - All Types

(1) Air / air exchanger (2) Air / water exchanger (3) Warm air metering device (4) Cold air metering device (5) Turbocharger (6) Flowmeter (7) Air filter BOSCH. BOSCH. ALLIEDSIGNAL GT1549P. SIEMENS. PSA 7885. INJECTION

B1HP1BYP

109

C5 - All Types

CHECKS : AIR SUPPLY CIRCUIT


Engine : 4HX

ESSENTIAL : Respect the safety and cleanliness recommendations. Tool. [1] Manual vacuum pump: FACOMM DA 16.

INJECTION
B1HP1ARP

Checks. ESSENTIAL : Respect the safety and cleanliness recommendations that are specific to high pressure diesel injection (HDi) engines.

110

CHECKS : AIR SUPPLY CIRCUIT


Engine : 4HX Vacuum pump. - Connect the tool [1] on the vacuum pump (3). - Start the engine. - The vacuum should be 0.8 bar at 750 rpm. Boost vacuum regulation electrovalve. - Connect the tool [1] between the electrovalve (2) and the valve (1). Compare readings with the values in the table below. Engine speed (rpm) Vacuum (Bar) 780 0.6 Bar 4000 0.25 Bar Boost pressure regulation valve. - Connect the tool [1] on the valve (1). (Grey marking on pipe). - Appy a vacuum of 0.8 bar. The rod "a" should move 12 2 mm. - Rod "a" should be moved 12 mm. Swirl control electrovalve. - Connect the tool [1] as an adaptor between the electrovalve (4) and the control diaphragm of the Swirl (5). - Compare readings with the values in the table below : Engine speed (rpm) Vacuum (Bar) 780 0.6 Bar 4000 0.25 Bar Swirl control diaphragm. - Connect the tool [1] on the control diaphragm of the Swirl (5). - Apply a vacuum of approx. 0.6 Bar ; the pin (6) should be at the end stop, at b. 111

C5 - All Types

INJECTION

C5 - All Types

CHECKS : EXHAUST GAS RECYCLING CIRCUIT


Engines : RHY - RHS - RHZ (1) Butterfly housing (2) EGR valve (tube with blue marking) (3) Electrovalve (black connector) (4) Electrovalve (blue connector) Tools : FACOM DA 16.

INJECTION
B1HP1BVD

[1] Manual vacuum pump

ESSENTIAL : Respect the safety and cleanliness requirements specific to high pressure diesel injection (HDi) engines. EGR electrovalve - Check, not under load, between the electrovalve (4) and the EGR valve (2). - Connect the tool [1] between the electrovalve (3) and the butterfly housing (1). - Compare readings with the values in the table below. Butterfly housing electrovalve. - Check, not under load, between the electrovalve (3) and the butterfly housing (1). - Connect the tool [1] between the electrovalve (3) and the butterfly housing (1). - Compare readings with the values in the table below. Engine speed (rpm) 780 2500 112 Vacuum value (bar) 0.5 Bar 0 Bar

CHECKS : EXHAUST GAS RECYCLING CIRCUIT


Engines : RHY - RHS - RHZ

C5 - All Types

EGR valve - Connect tool [1] on the EGR valve capsule take-off (2). - Apply a vacuum of approx. 0.6 bar to activate the EGR valve. - In abruptly suppressing the vacuum, the valve should click and lock itself back on its seating. - Repeat the operation several times. INJECTION

Butterfly housing - Remove the air duct between the air/air exchanger and the butterfly housing (5), (1). - Connect tool [1] on the butterfly housing vacuum capsule (1). - Apply a vacuum of approx. 0.8 bar, the flap (a) of the butterfly housing (1) should be closed.

B1HP1BWC B1BP2ADC

113

C5 - All Types

CHECKS : EXHAUST GAS RECYCLING CIRCUIT


Engine : 4HX TOOLS [1] Manual vacuum pump : FACOM DA 16.

ESSENTIAL : Respect the safety and cleanliness requirements specific to high pressure diesel injection (HDi) engines. Electrovanne (EGR). - Check, not under load, between the electrovalve (3) (blue connector) and the EGR valve (2) (tube with blue marking). - Connect the tool [1] between the electrovalve (3) and the EGR valve (2). - Compare readings with the values in the table below. Butterfly housing electrovalve - Check, not under load, between the electrovalve (4) (black connector) and the butterfly housing (1) (Metering pump cold), (tube with white marking). - Connect the tool [1] between the electrovalve (4) and the butterfly housing (1). - Compare readings with the values in the table below. Engine speed (rpm) 780 2500
B1HP1B8D

INJECTION

Vacuum value (bar) 0.5 Bar 0 Bar

114

CHECKS : EXHAUST GAS RECYCLING CIRCUIT


Engine : 4HX

C5 - All Types

- Connect tool [1] on the take-off (a) of the EGR valve capsule (2). - Apply a vacuum of approx. 0.6 bar to activate the EGR valve. - In abruptly suppressing the vacuum, the valve should click and lock itself back on its seating. - Repeat the operation several times.

Butterfly housing - Remove the air duct between the air/air exchanger and the butterfly housing (1). - Disconnect the tube (white marking) on the electrovalve (4) (black connector). - Connect tool [1] on the tube with the white marking. - Apply a vacuum of approx. 0.8 bar, the flap (b) of the butterfly housing (1) should be closed.

B1BP29NC

B1BP29PC

115

INJECTION

EGR valve

C5 - All Types
Engine : RHY

CHECKS : TURBO PRESSURE


Engines : RHY - RHS - RHZ TOOLS. [1] Pressure gauge for checking boost pressure [2] Sleeve for checking boost pressure [3] Adaptor sleeve Checks. Preparation for RHY engine Remove : - The collars (3). - The sleeve. - Insert the tool [2] between the tube (1) and the duct (2). - Position the tool [1] in the vehicle. - Connect the pressure gauge [1] to the tool [2] with its tube (a) long enough for the gauge to be positioned inside the vehicle. Checks. Preparation for RHZ engine - Remove the collar fixing (3). - Insert the tool [2] equipped with tool [3], between the tube (1) and the duct (2). - Position the tool [1] in the vehicle. - Connect the sleeve [2] on the pressure gauge [1] with the tube (a).
B1BP1ZXD BHP12JD

: 4073-T.A Kit 4073-T : 4185-T : 4219-T

INJECTION Engines : RHS - RHZ

116

CHECKS : TURBO PRESSURE


Engines : RHY - RHS - RHZ Procedure.

C5 - All Types

- Start the engine. - Engage first gear and start the vehicle. - Engage the gears up to third gear. - Decelerate to 2000 rpm. - Gradually accelerate. - Check the pressure : 0.95 0.05 Bar - Remove the tools [1] and [2] Refit: - The sleeve. - The collars (3). - Tighten the collars (3).

C5FP0ACC

117

INJECTION

ESSENTIAL : Observe the following checking requirements : - Engine at running temperature. - Vehicle in running order. - Engine at full load.

C5 - All Types

CHECKS : TURBO PRESSURE


Engine : 4HX TOOLS. [1] Pressure gauge for checking pressure [2] Extension cable for taking pressure [3] Union and hose for taking pressure [4] Adaptor for taking pressure [5] Unions and hoses for taking pressure 7073-T.A. 8607-T.A 8607-T.B. 8607-T.C. 4088-T

INJECTION

Checks. ESSENTIAL : Respect the safety and cleanliness requirements specific to high pressure diesel injection (HDi) engines. Preliminary operations. Carry out the following operations: Remove the screw (1). Disconnect the tube (2). Move aside the pressure sensor (3). Preparation of tools : in position on the vehicle. Fit as follows : Remove the hose (a) of tool [5], screw in its place the tool [3], remove the hose (b) of tool [5], screw the hose (b) of tool [5] on the pressure gauge [1], screw the adaptor [4] onto the tool [5]. Connect the tube (2) of the pressure sensor (3) on the tool [4], tighten the tube (2) with a Serflex type collar.
B1BP28DC E5AP1SUC

118

CHECKS : TURBO PRESSURE


Engine : 4HX Preparation of tools : in position on the vehicle (continued). Screw the tool [3] on the take-off of the turbo air radiator at c. Place the pressure gauge on the cup holder at d.. Connect the extension [2] on the hose b and tool [5]. ESSENTIAL : Observe the following checking requirements. - Start the engine. - Engage first gear and start the vehicle. - Engage the gears up to third gear. - Decelerate to 1500 rpm. Accelerate gradually : the pressures should be the following : 1.1 0.05 b at 2000 rpm 1.2 0.05 b at 3000 rpm. Return the vehicle to normal. Remove the tools [1], [2], [3], [4] and [5]. Reposition the pressure sensor (3). Couple the tube (2). Refit and tighten the screw (1).

C5 - All Types

B1BP28EC

C5FPOBLC

119

INJECTION

C5 - All Types
Emission standard Equipment INJECTION C5 DW 10 RHY

SPECIFICATIONS OF THE SIEMENS INJECTION PUMP


PUMP -TYPE - REFERENCE L3 / L4 Transponder

RHS

SIEMENS 5WS 40001

RHZ

120

SPECIFICATIONS OF THE SIEMENS INJECTION PUMP


PUMP -TYPE - REFERENCE Emission standard Equipment L3 / L4 Transponder

SYNERGIE

SYNERGIE

DW

10

RHZ

CP1 (*)

( ) = The fuel high pressure pump is driven by the timing belt.

121

INJECTION

SYNERGIE

FITTING BOSCH INJECTORS


Engines : RHY - RHZ Evolution : Classification of diesel injector carriers

16/11/98
INJECTION
B1HP16PC

Reminder : RHY and RHZ are equipped with 4 diesel injector carriers marked according to their injection duct diameters (flow of diesel fuel). Identification. The injector carriers have an engraving or paint mark on the upper part of the coil, close to the diesel fuel return aperture : Mark 1 = BLUE paint mark = Injector class 1. Mark 2 = GREEN paint mark = Injector class 2. Identification marking: a : Supplier identification. b : PSA identification no. c : Identification of class. After Sales operations. ESSENTIAL : When changing a diesel injector carrier, order a component of the same class.

# 15/11/98 (RPO No.) (injector carrier without marking), always order a class 2 injector carrier.
122

SPARKING PLUGS
Vehicles - Models 1.8I 16V C5 2.0i 16v 2.0i HPi 3.0i 24S SYNERGIE 2.0i 16v Engine type 6FZ RFN RLZ XFX RFN BOSCH CHAMPION EYQUEM

SYNERGIE - C5
Electrode gap Tightening torque (m.daN)

FR8ME ZR8TPP15 FGR8MQPE FR8ME

REC94CL

RFN52HZ 1 mm

2.75 0.2

2.25 0.2 REC9YCL RFN52H2 2.75 0.2

123

ALLUMAGE

ALL TYPES

SPEEDOMETER

An E.E.C. decree of 25 June 1976, regulates the speed displayed by the speedmeter in relation to the actual speed travelled. This decree stipulates : - The speed indicated by a speedometer must never be lower than the actual vehicle speed. - Between the speed displayed SD and the speed travelled ST, there must always be the following relationship :

VR < VL < 1.10 VR + 4 Km/h


Example : For an actual speed of 100 Kph the speed displayed by the speedometer may be between 100 and 114 Kph. The speed indicated by the speedometer may be influenced by : - The speedometer. - The tyres fitted to the vehicle. - The final drive ratio. - The speedometer drive ratio. Any of these components can be checked without removing them from the vehicle. (See information note N 78-85 TT of 19 October 1978). NOTE : Before replacing the speedometer, check the conformity of the following points : - The tyres fitted to the vehicle. - The gearbox final drive ratio. - The speedometer drive ratio. 124 EMBRAYAGE BV TRANSMISSION

CLUTCH SPECIFICATIONS
Petrol 1.8i 16V Engine type Gearbox type Supplier Mechanism / type Clutch disc of lining. Ext/Int Quality of lining F 808 F 410 11 R 10X 230 DNG 4700 12 R 14X 228/155 F 808 DS 6FZ BE4/5 VALEO 230 DING 4700 228 D 73 12 R 14 X 230 DNG 4700 R 11 R 14X 242 T 6500 11 A 14X 242/162 F 410 2.0i 16V RFN 2.0 HPi RLZ ML/5 3.0i V6 XFX

125

CLUTCH GEARBOX DRIVESHAFTS

CLUTCH SPECIFICATIONS
Diesel 2.0 HDi Engine type Gearbox type Supplier Mechanism / type Clutch disc of lining. Ext/Int Quality of lining 228/155 F 408 225/150 F 808 230 P 4700 225 T 5700 RHY BE4/5 LUK 242 T 6500 Damping performed by engine flywheel 242/162 RHS RHZ ML/5 2.2 HDi 4HX

CLUTCH GEARBOX DRIVESHAFTS

126

BE4/5 GEARBOX CONTROL SPECIFICATIONS


Engines : 6FZ - RFN - RLZ - RHY

C5 - All Types

Gear controls

[1] Gear lever positioning tool 8605-T.

(1) (2) (3) (4) (5) (6)

Gear engagement ball-joint 10 mm. Gear control lever Gear engagement control cable. Gear selection control cable. Cable selection locking ley. Gear selection ball-joint 10 mm. CLUTCH GEARBOX DRIVESHAFTS

B2CP3CJD

127

C5 - All Types
Gear selection control cable.

BE4/5 GEARBOX CONTROL SPECIFICATIONS


Engines : 6FZ - RFN - RLZ - RHY Gear engagement control cable.

B2CP3CKD

B2CP3CLD

Left hand drive Length A Length B Note : See adjustment - page 129. CLUTCH GEARBOX DRIVESHAFTS

Right hand drive Length G Length H

Left hand drive

Right hand drive

730 3mm 937.5 7.5mm

700 3 mm 983 7.5 mm

128

CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS


Engines : 6FZ - RFN - RLZ - RHY

C5 - All Types

Adjustments. WARNING : Control cables should be adjusted each time the gearbox is removed or cables changed.

WARNING : Do not use oil to detach the ball-joints. To release the ball-joint, press at the centre a then pull the ball-joint upwards. Ball-joints alone can be changed by removing the unlocking key with the aid of two thin screwdrivers, unclip at b. To unlock the ball-joint, turn in the direction of the arrow c. CLUTCH GEARBOX DRIVESHAFTS

B2CP3CVD

B2CP3CWC

B2CP3CXC

129

C5 - All Types

CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS


Engines : 6FZ - RFN - RLZ - RHY

Tools. [1] Tool for positioning the gearbox control lever 8605-T Toolkit 9040-T

Adjustments. Cables should be adjusted each time the gearbox, gear controls or power unit are removed Adjustment principles : - Lock the gear lever in neutral position, using tool [1]. - Position the gearbox in neutral. - Anchor the ball-joints on the gearbox levers. - Lock the cable lengths with the ball-joint locking keys. Inside the vehicle. - Remove the central console (See corresponding operation). - Remove the plastic blank at (a). - Insert tool [1] fully and rotate a quarter turn to lock the gear control lever. - At neutral.

CLUTCH GEARBOX DRIVESHAFTS

B2CP3E7C

130

CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS


Engines : 6FZ - RFN - RLZ - RHY

C5 - All Types

Adjustments (continued) Under the bonnet. - Remove the air filter assembly. - Unlock the gear engagement cable ball-joint (b). - Unlock the gear selection cable ball-joint (c). - Make sure the gear levers (engagement and selection) are in neutral position. - Lock the cable lengths with the ball-joint locking keys. - Remove the tool [1]. Checks. Remove the tool [1]. Check that all the gears engage without tightness. Check that the gear lever moves identically forwards and backwards and to right and left. If not : Repeat the adjustment.

Refit the console and the air filter assembly.


B2CP3E8C B2CP3E9C

131

CLUTCH GEARBOX DRIVESHAFTS

C5 - All Types

ML/5 GEARBOX SPECIFICATION


Engines : XFX - RHZ - RHS - 4HX

[1] Gear lever positioning tool

8605-T.

(1) (2) (3) (4) (5)

Gear Gear Gear Gear Gear

engagement ball-joint 10 mm. control lever engagement control cable. selection control cable. selection ball-joint 10 mm.

CLUTCH GEARBOX DRIVESHAFTS

B2CP3CQD

132

ML/5 GEARBOX SPECIFICATION


Engines : XFX - RHZ - RHS - 4HX Gear selection control cable. Gear engagement control cable.

C5 - All Types

B2CP3CRD

B2CP3CSD

Left hand drive Length A Length B Note : See adjustment - page 134.

Right hand drive Length C Length D

Left hand drive

Right hand drive CLUTCH GEARBOX DRIVESHAFTS

750 3mm 1012 7.5mm

771 3 mm 1094 7.5 mm

133

C5 - All Types

CHECKS AND ADJUSTMENTS : ML/5 GEARBOX CONTROLS


Engines : XFX - RHZ - RHS - 4HX

Adjustments.

WARNING : Control cables should be adjusted each time the gearbox is removed or cables changed.

WARNING : Do not use oil to detach the ball-joints. To release the ball-joint, press at the centre a then pull the ball-joint upwards. Ball-joints alone can be changed by removing the unlocking key with the aid of two thin screwdrivers, unclip at b.

CLUTCH GEARBOX DRIVESHAFTS

B2CP3CTD

B2CP3BYC

134

CHECKS AND ADJUSTMENTS : ML/5 GEARBOX CONTROLS


Engines : XFX - RHZ - RHS - 4HX Tools [1] Tool for positioning the gearbox control lever Adjustments. 8605-T

C5 - All Types

Toolkit 9040-T

Cables should be adjusted each time the gearbox, gear controls or power unit are removed. Adjustment principles : - Lock the gear lever in neutral position, using tool [1]. - Position the gearbox in neutral. - Anchor the ball-joints on the gearbox levers. - Lock the cable lengths with the ball-joint locking keys. Inside the vehicle. - Remove the central console (See corresponding operation). - Remove the plastic blank at (a). - Insert tool [1] fully and rotate a quarter turn to lock the gear control lever. - At neutral.
B2CP3E7C

135

CLUTCH GEARBOX DRIVESHAFTS

C5 - All Types

CHECKS AND ADJUSTMENTS : ML/5 GEARBOX CONTROLS


Engines : XFX - RHZ - RHS - 4HX

Adjustments (continued) Under the bonnet. Remove the air filter assembly. Unlock the gear engagement and selection cable ball-joint (b). Make sure the gear levers (engagement and selection) are in neutral position. Lock the cable lengths with the ball-joint locking keys. Remove the tool [1].

Checks. Remove the tool [1]. Check that all the gears engage without tightness . Check that the gear lever moves identically forwards and backwards and to right and left. If not : Repeat the adjustment. Refit the console and the air filter assembly.

CLUTCH GEARBOX DRIVESHAFTS

B2CP3EBC

136

BE4/5 GEARBOX CONTROL SPECIFICATIONS


Engines : RFN

SYNERGIE

(1) Gear control lever (2) Gear engagement control cable (*) (3) Gear selection control cable (*) (4) Gear selection ball-joint 10 mm. (5) Gear engagement ball-joint 10 mm. (6) Flexible insulating grommet through the bulkhead.

B2CP3BWD

137

CLUTCH GEARBOX DRIVESHAFTS

(*) = These two cables cannot be separated.

SYNERGIE

CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS


Engines : RFN Principles of adjusting the gear controls. WARNING : Cables should be adjusted each time the gearbox, gear controls or power unit are removed.

Principles. Lock the gear lever in neutral position, using tool: 9607-T. Place the gearbox in neutral. Couple the cables on the lever. Fit the ball-joints on the gearbox lever. Lock the cable lengths with the ball-joint locking keys. CLUTCH GEARBOX DRIVESHAFTS

WARNING : Do not use any tool to unclip the ball-joints. To unlock the ball-joint, press at the centre a, then pull the ball-joint upwards.

NOTE : Changing an individual ball-joint is possible as long as the locking key is removed. Unclip at b, using two small screwdrivers.

B2CP3BXC

B2CP3BYC

138

CHECKS AND ADJUSTMENTS : BE4/5 GEARBOX CONTROLS


Engines : RFN Adjusting the gear controls. TOOLS : [1] Tool for positioning the gear lever ADJUSTMENTS. WARNING : Cables should be adjusted each time the gearbox, gear controls or power unit are removed. Inside the vehicle. - Remove the trim under the gear lever. - Lock the gear lever in neutral position, using tool [1]. Under the bonnet. - Remove the air filter assembly. - Unlock the ball-joint keys at a. - Place the gear selection and control levers neutral. - Lock the cable lengths with the ball-joint locking keys.

SYNERGIE

: 9607-T. CHECKS. - Remove the tool [1]. - Check that all the gears engage without tightness . - Check that the gear lever moves identically forwards and backwards and to right and left. If it does not, repeat the adjustment. - Refit the trim under the gear lever. - Refit the air filter assembly.

B2CP3C6C

B2CP3C0C

139

CLUTCH GEARBOX DRIVESHAFTS

SYNERGIE

CLUTCH : CHECKS AND ADJUSTMENTS


Engines : RFN - RHZ WARNING : If a system blockage is detected when checking, or if the pedal has been removed, the pedal position must be adjusted. This position is obtained by the angular displacement of the stop supports "a" and "b". Procedure. - Loosen the nut (6) and the screw (7). - Using a lever, raise the stop support (8) to its highest position. - In this position, there must be a substantial free play in the pedal. - Lower the support until there is a free play of 2 1 mm. - Tighten the screw (7) and the nut (6). - Check that the outer cable slides freely (at rest, the pedal is against its upper stop A, the outer cable length should be variable). Characteristics - The automatic adjusting device requires no manual adjustment. - Pedal travel remains constant for all models 145 5 mm. - Automatic adjustment is achieved by modifying the curvature of the outer cable. - Take extra care with the routing of the outer cable, and do not add any supplementary fixing points.

Adjustment of push and pull action clutch with automatic compensation (adjustment of compensation system)

CLUTCH GEARBOX DRIVESHAFTS

B2BP03EC

140

CLUTCH : CHECKS AND ADJUSTMENTS


Engines : RFN - RHZ

SYNERGIE

B2BP02SC

NOTE : This cable has an automatic adjusting device which takes up the clutch disc wear and makes up for the compression of the outer cable. DESCRIPTION 5 - Tensioning spring ensuring the maximum length of the outer cable. 6 - Wear take up device. 7 - Attaching end-piece.

1 2 3 4

Metallic cable, crimped on both ends. Outer cable or telescopic duct. Outer cable stop, bulkhead side (fixed point on the bodyshell). Outer cable stop, gearbox side (fixed point on the gearbox).

141

CLUTCH GEARBOX DRIVESHAFTS

SYNERGIE

CLUTCH : CHECKS AND ADJUSTMENTS


Engines : RFN - RHZ (continued)

B2BP03QD

Operation For the adjusting device to operate correctly, it is necessary that : The pedal is at rest (against its upper stop) The locking sleeve (1) is slightly compressed, the rollers (2) are free, the outer cable (3) length may vary.

Clutch disengagement phase As soon as the pedal is applied, the attaching end-piece (4) leaves the sleeve (1) which moves back. The rollers, pushed by spring (5) jam the system. The cable behaves like a conventional cable.

Engagement / adjustment phase The pedal returns to rest on its upper stop. Attaching end-piece (4) pushes sleeve (1) which frees the rollers. Outer cable (3), kept extended by the spring (6) becomes : - Shorter if the clutch disc is worn. - Longer if the outer cable has been compressed.

CLUTCH GEARBOX DRIVESHAFTS

NOTE : The pedal gear has a non-adjustable assisting device. 142

CLUTCH : CHECKS AND ADJUSTMENTS


Hydraulically operated pull-action clutch (Non-adjustable) Engine Synergie : RHZ Gearbox ML/5

SYNERGIE

B2BP03RC

E5AP14VC B2BP03SC

(1) Quick-fit union: Tool 9040-T.H. 143

CLUTCH GEARBOX DRIVESHAFTS

SYNERGIE

CLUTCH : CHECKS AND ADJUSTMENTS


Hydraulically operated pull-action clutch (Non-adjustable) Engine : RHZ A Old assembly, supplied complete and filled with hydraulic fluid. B New assembly : - The components supplied separately. - The circuit is filled with fluid after being fitted to the vehicle. (1) Clutch master cylinder. (2) Clutch slave cylinder. (3) Hydraulic clutch control reservoir. (4) Link pipe. (5) Click-fit union, sealed (after dismantling). (6) Click-fit union, non-sealed (after dismantling). (7) Bleed screw. The new assembly consists of the the following parts : - Clutch master cylinder, anchored in place after a 1/4 turn. - Clutch slave cylinder, with push-rod. - Hydraulic clutch control reservoir, with feed pipe. - Link pipe, between master cylinder and slave cylinder.

CLUTCH GEARBOX DRIVESHAFTS

B2BP03ZD

144

CLUTCH : CHECKS AND ADJUSTMENTS


Hydraulically operated pull-action clutch (Non-adjustable) Engines : RHZ

SYNERGIE

B2BP03ZD

145

CLUTCH GEARBOX DRIVESHAFTS

After fitting on the vehicle, the circuit should be filled with a DOT 4 type brake fluid. Clutch control reservoir capacity 120 cc. (Bleeding is carried out not under pressure). Repair. The new clutch control components are not compatible with the old parts. Both the old and the new components are marketed by Replacement Parts . Draining Filling - Top-up. - Check the level after each repair visit. - Fill the circuit (after drainage), using a filling cylinder specifically designed for this operation. - Use the circuits bleed screw (7). - The level of fluid inside the clutch control reservoir should be between the min. and max. marks. NOTE : Wear on the clutch causes a slight increase in the level of fluid inside the control reservoir.

SYNERGIE

ML/5 GEARBOX CONTROLS


Engine : RHZ

CLUTCH GEARBOX DRIVESHAFTS

B2CP16FP

146

GEARBOX AND TYRE SPECIFICATIONS


Petrol 18i 16V Automatic Engine type Tyres-Rolling circumference Gearbox type Gearbox ident. plate Reduction box torque Speedometer ratio 6FZ 195/65 R15 1.93 m BE4/5 20 DL 29 19x79 22x18 AL4 20 TP 44 21x73 52x67 Petrol 3.0i V6 Automatic Engine type Tyres-Rolling circumference Gearbox type Gearbox ident. plate Reduction box torque Speedometer ratio ML/5C 20 LE 95 16x65 None 147 XFX 215/55 R16 1.96 m 20 LE 95 20 HZ 13 20x69 59x68 BE4/5 20 DL 30 19x79 22x18 RFN 195/65 R15 1.93 m AL4 20 TP 42 23x73 52x67 2.0i 16V Automatic

C5 - All Types
2.0 HPi RLZ

BE4/5 20 DL 31 19x77 None

CLUTCH GEARBOX DRIVESHAFTS

ML/5T

4 HP 20

C5 - All Types

GEARBOX AND TYRE SPECIFICATIONS


Diesel 2.0 HDi Automatic 2.2 HDi RHS - RHZ 195/65 R15 1.93 m BE4/5 20 DL 32 19x75 None Diesel 2.2 HDi Automatic ML/5C 20 LM 18 16x65 None ML/5T 20 LE 94 AL4 20 TP 43 25x68 52x67 4HX 215/65 R16-1.96 m ML/5C 20 LM 17 17x67 None

Engine type Tyres-Rolling circumference Gearbox type Gearbox ident. plate Reduction box torque Speedometer ratio

RHY

Engine type Tyres-Rolling circumference Gearbox type Gearbox ident. plate Reduction box torque Speedometer ratio CLUTCH GEARBOX DRIVESHAFTS

4HX 215/65 R16-1.96 m ML/5T 20 LE 96 17x67 None 4 HP 20 20 HZ 20 23x66 59x68 148

GEARBOX AND TYRE SPECIFICATIONS


Petrol 2.0i 16V Engine type Tyres-Rolling circumference Gearbox type Gearbox ident. plate Reduction box torque Speedometer ratio 20 DL 26 14x62 18x14 BE4/5 20 DL 27 RFN 205/65 R15 - 1.97 m AL4 20 TP 31 21x73 20x16 Automatic

SYNERGIE
Diesel 2.0 HDi RHY ML/5 20 LE 91 (*) 15x67 25x20

(*) DVA = Double Damped Flywheel

149

CLUTCH GEARBOX DRIVESHAFTS

SYNERGIE - C5

BE4/5 GEARBOX
Engine : RFN

CLUTCH GEARBOX DRIVESHAFTS

(a) Marking zone (sequence and serial no.). (b) Location of identification label.

B2CP3BNC

B2CP3BPD

150

BE4/5 GEARBOX
Engine : RFN Description (1) Primary shaft. (2) Clutch bearing guide. (3) Gearbox casing. (4) Clutch housing. (5) Reverse idle. (6) Drive gear (3rd gear). (7) 3rd /4th gear synchroniser (8) Drive gear (4th gear). (9) Drive gear (5th gear). (10) 5th gear synchroniser. (11) Driven gear (5th gear). (12) Driven gear (2nd / 4th gear ) (13) Driven gear (2nd gear).

SYNERGIE - C5

(14) (15) (16) (17) (18) (19) (20) (21) (22)

1st / 2nd gear synchroniser Driven gear (1st gear). Secondary shaft. Differential gear. Satellite gears. Planet gears. Differential housing. Speedometer drive. Extension.

d Adjusting shims : 0,7 to 2,4 mm. (From 0,10 to 0,10 mm) c Adjusting shims : 1,4 to 1,6 mm. (From 0,10 to 0,10 mm) CLUTCH GEARBOX DRIVESHAFTS

B2CP3BQP

151

SYNERGIE - C5

BE4/5 GEARBOX
Engine : RFN Tightening torques Ref. 1 2 3 4 5
B2CP3BSP

Description End guide Clutch housing Primary shaft nut Secondary shaft nut Yoke holding screw Differential gearwheel screw Reverse gear contact

Number of screws 3 13 1 1 2 2 1 4 1 7 1 4 1

m.daN 1.2 0.1 1.3 0.1 7.2 0.7 6.5 0.7 1.5 0.1 6.5 0.7 2.5 0.3 5 0.5 1.7 0.2 1.2 0.1 2.2 0.2 1.2 0.1 3.5 0.4

7 8 9 CLUTCH GEARBOX DRIVESHAFTS 10 11


B2CP3BTD

Differential housing Breather pipe Rear housing cover screw Top-up plug Differential housing screw Drain plug screw 152

12

ML/5 GEARBOX SPECIFICATION


Engines : XFX - RHZ - RHS - 4HX Identification.

C5 - All Types

Identification

(a) Marking zone (Sequence and serial no.). (b) Location of identification label.

B2CP3CMC

153

CLUTCH GEARBOX DRIVESHAFTS

C5 - All Types

ML/5 GEARBOX SPECIFICATION


Engines : XFX - RHZ - RHS - 4HX Identification (continued) (1) Primary shaft. (2) Clutch bearing guide. (3) Clutch housing (4) Gearbox casing. (5) Oil channel (6) Primary shaft bearing adjustment shim. (7) Drive gear (5th) (8) Secondary shaft. (9) Driven gear (1st) (10) Satellite gears. (11) Speedometer screw. (12) Speedometer drive. (13) Planet gears. (14) Differential housing (15) Differential gearwheel. (16) Differential bearing stop plate. (17) 1st/2nd gear synchroniser and reverse gear driven gear. (18) (19) (20) (21) (22) (23) (24) Driven gear (2nd) Driven gears (3rd) 3rd/4th gear synchroniser. Driven gears (4th) Driven gears (5th) 5th gear synchroniser. Planet gear adjustment shim.

Tightening torques m.daN.

(25) Clutch bearing guide (26) Secondary shaft nut (27) Differential screw

2 0,2 17 1,5 7,5 0,5

CLUTCH GEARBOX DRIVESHAFTS

B2CP3CNP

154

ML/5 GEARBOX SPECIFICATION


Engines : XFX - RHZ - RHS - 4HX Identification (continued)

C5 - All Types

Tightening torques m.daN.

(28) (29) (30) (31) (32) (33) (34) (35) (36)

Reverse lamp switch Gearbox casing /clutch housing fixing screws Differential bearing stop plate screws Gearbox rear casing screws Drain plug Filling / top-up plug M8 screw (Differential housing fixing) M10 screw (Differential housing fixing) Selector guide screw

2,5 0,2 2 0,2 2 0,2 2 0,2 3 0,3 3 0,3 2 0,2 4 0,5 4 0.5 CLUTCH GEARBOX DRIVESHAFTS

B2CP3CPD

155

C5 - All Types

ML/5 GEARBOX SPECIFICATION


Engines : XFX - RHZ - RHS - 4HX Recommendations - Precautions

(1) Drain plug. (2) Filler and top-up plug.

Oil quality. - See chapter on lubricants: page 19.

Oil quantity. - After draining CLUTCH GEARBOX DRIVESHAFTS

= 1.8 litres

B2CP3CUC

156

4 HP 20 AUTOACTIVE GEARBOX SPECIFICATION


Engines : XFX - 4HX Identification. (1) Identification plate (riveted on the casing). (a) Serial no. (b) ZF number. (last digits taken into account) (c) Type of automatic gearbox. (d) Component reference

C5 - All Types

B2CP3CYD

157

CLUTCH GEARBOX DRIVESHAFTS

Oil quality and quantity (See chapter, page 19).

C5 - All Types

4 HP 20 AUTOACTIVE GEARBOX SPECIFICATION


Engines : XFX - 4HX

Tightening torques m.daN. Gearbox exterior. (2) (3) (4) (5) (6) (7) (8) Oil channel union fixing Exteror fixing of Exterior fixing of converter cover on clutch housing Speedometer take-off aperture plug Steel casing fixing Converter fixing on engine Interior fixing of converter cover on clutch housing Torx fixing of converter cover on clutch housing 2.5 0.5 2.3 0.5 1 0.1 0.6 0.1 61 2.3 0.5 2.3 0.5 4.5 0.8 3.5 0.5 1 0.2 6.5 1 5.8 1

Drain plug Heat exchanger fixing Selector lever position switch fixing Converter cover fixing on engine cover (XFX engine) Converter cover fixing on engine cover (4HX engine)

CLUTCH GEARBOX DRIVESHAFTS

B2CP3CZC

B2CP24BC

B2CP24CC

158

4 HP 20 AUTOACTIVE GEARBOX SPECIFICATION


Engines : XFX - 4HX

C5 - All Types

Tightening torques m.daN.

Gearbox interior. (9) Input speed sensor fixing (10) Hydraulic block fixing (Large head) (11) Output speed sensor fixing 0.8 0.1 0.8 0.1 1 0.2

B2CP24DC

B2CP24EC

159

CLUTCH GEARBOX DRIVESHAFTS

C5 - All Types

RECOMMENDATIONS - PRECAUTIONS (AL 4 and 4 HP 20 AUTOMATIC GEARBOXES)


Engines : 6FZ - RFN - RHZ - XFX - 4HX Precautions to be taken

Towing. The front of the vehicle must be raised in order to be towed. If the front of the vehicle cannot be raised : IMPERATIVE : - Put gear lever in position N. - Do not add any oil. AL4 gearbox - Do not exceed 50 km/h (30mph) over a distance of 50 km (30m). 4 HP 20 gearbox - Do not exceed 70 km/h (45mph) over a distance of 100 km (60m). Driving. Never drive with the ignition switched off. Never push the vehicle to try to start it; (impossible with an automatic gearbox). Lubrication The automatic gearbox is only lubricated when the engine is running.

REMOVING - REFITTING. (Automatic gearbox). WARNING : Never place the gearbox on its lower casing (risk of deforming the tray and damaging the hydraulic valve block). Never use the connections as handles for raising, turning, holding or pushing the gearbox. ESSENTIAL : - Fit the converter retaining peg while the gearbox is removed. - Fit the centring peg to locate the gearbox on the engine: (remove the converter retaining peg just before locating) WARNING : With the emergency programme selected, an impact is felt when changing from P R ou N R.

CLUTCH GEARBOX DRIVESHAFTS

160

RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX)


Engines : 6FZ - RFN - RHZ Procedure to be followed prior to carrying out repairs on AL4 autoactive gearbox If a gearbox malfunction occurs, there are two possible configurations depending on the seriousness of the fault : - Gearbox in back-up mode with a replacement programme of (the fault values are taken in substitution). - Gearbox in back-up mode with an emergency programme (3rd hydraulic) WARNING : In the emergency programme, an impact is felt when changing P/R, N/R and N/D. Rception client. Discuss with the customer, to find out all the malfunction symptoms.. Oil quality Oil level. Oil quality. If the gearbox has suffered a serious fault resulting in a malfunction or the destruction of a clutch, the oil will overheat and become contaminated with impurities : the oil is said to be burnt. This is characterised by a black colour and the presence of an unpleasant smell. ESSENTIAL : The gearbox must be replaced.

C5 - All Types

161

CLUTCH GEARBOX DRIVESHAFTS

Oil level. See corresponding operation. An excessive oil level can result in the following consequences : - Excessive heating of the oil. - Oil leaks. An insufficent level causes the destruction of the gearbox. Top up the level of oil in the gearbox (if necessary). Check using a diagnostic tool. Read the fault codes (engine and gearbox). Absence of fault codes. Carry out parameter measures, actuator tests and a road test. Presence of fault codes. Carry out the necessary repairs. Delete the fault codes. Carry out a road test to check the repair and, if need be, modify the gearbox ECU parameters (this is essential after an initialisation of the ECU).

C5 - All Types

RECOMMENDATIONS - PRECAUTIONS (AL 4 and 4 HP 20 AUTOMATIC GEARBOXES)


Engines : 6FZ - RFN - RHZ - XFX - 4HX Procedure prior to carrying out repairs (continued)

When the ECU detects an erroneous or non-existent value on input or output : - It writes the fault in memory. - For each associated context, it writes the context of the oldest fault in memory. - It initiates a back-up mode strategy. There are two types of back-up modes : - The ECU makes replacement values available (relating to comfort, gear selection quality, loss of functions). - Access to emergency programme (only 3rd ratio and reverse are available) NOTE : 4 HP 20 : A snatching may be felt when changing : P/R - N/R - N/D. CLUTCH GEARBOX DRIVESHAFTS

Reading the fault codes. Read the fault codes. No fault codes present : Carry out a measure of parameters. Anomalies present : YES : Carry out the necessary repairs. NO : Read the fault codes engine ECU - Carry out a road test. Following an initialisation of the ECU, for a certain period of time there may be an inconsistent gear selection quality (while ECU parameters are adapted to the gearbox). To achieve a consistent standard, it is necessary to carry out a road test taking in frequent gear changes (auto-adaptive laws).

162

RECOMMENDATIONS - PRECAUTIONS (AL 4 and 4 HP 20 AUTOMATIC GEARBOXES)


Engines : 6FZ - RFN - RHZ - XFX - 4HX ECU : Downloading, Configuration, Initialisation (Pedal). Downloading. (AL 4 and 4 HP 20) Updating the gearbox ECU by downloading : - Follow the procedure using the diagnostic equipment. The operation of downloading is used to update the automatic gearbox ECU or to adapt it to evolutions of the engine ECU. After downloading, carry out the following : - Note down the value in the oil usage counter present in the automatic gearbox ECU. - Delete the fault codes. - Again note down the value in the oil usage counter and compare it with the value previously read. - Pedal initialisation (AL 4) - Configuration (if needed) (AL 4) Following the diagnostic tool procedure. - A reinitialisation of the autoadaptives (AL4 and 4 HP 20). - A road test (AL 4 and 4 HP 20).

C5 - All Types

IMPERATIVE : Every update of the automatic gearbox ECU must be accompanied by an update of the engine ECU.

163

CLUTCH GEARBOX DRIVESHAFTS

C5 - All Types

RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX)


Engines : 6FZ - RFN - RHZ ECU : Downloading, Configuration, Initialisation (Pedal) (continued)

Downloading (AL 4 only). ECU downloading procedure : - Follow the diagnostic tooling procedure. A new ECU or downloaded update is always configured with the following options : - SHIFT LOCK gear selection lever position. - OBD outlet (emission standard L4). If the ECU is to be fitted to a vehicle without one or both of these options: - Carry out a configuration which inhibits the diagnosis of the option(s) concerned. CLUTCH GEARBOX DRIVESHAFTS

Pedal initialisation. (AL 4 only). A pedal initialisation must be carried out in the following cases : - Replacement of the automatic gearbox ECU. - Replacement of the automatic gearbox. - Downloading of the ECU configuration. - Adjustment or replacement of the accelerator cable. - Replacement of the throttle potentiometer.

- IMPERATIVE : For a certain period of time, while the ECU parameters are adapted to the gearbox, there may be an inconsistent gear selection quality. To achieve a consistent standard, it will be necessary to carry out a road test taking in frequent gear changes (auto adaptive laws).

164

RECOMMENDATIONS - PRECAUTIONS (4 HP 20 AUTOMATIC GEARBOX)


Engines : XFX - 4HX SHIFT LOCK The shift lock is a system which locks the gear selection lever in the park position P. Unlocking the shift lock (normal operation). Switch on the ignition. Apply the brake pedal and keep it pressed. Using the selection lever, disengage from position P. Unlocking the shift lock (with a fault). NOTE : It is impossible to unlock the shift lock with the normal operation method. The causes of the fault may arise from the following components : - Shift lock. - Gear lever position switch. - Automatic gearbox ECU. - Electrical harnesses. - Battery voltage. Remove : - The gear lever knob (1) by pulling upwards. - The cover (2) (unclip). - The shutter. Unlock the shift lock (4) using a screwdriver. Using the selection lever, disengage from position P.
C5FPOCUD C5FPOCTC

C5 - All Types

165

CLUTCH GEARBOX DRIVESHAFTS

4 HP 20 GEARBOX CONTROLS
Engines : XFX - 4HX Selection control. The gear selection control has 5 positions. The selection lever is guided by the shape of the stepped gate and by a retaining spring which holds it towards the left. The gear selection control is equipped with the shift lock, so you have to switch on the ignition and apply the brake pedal to unlock the selection lever from the park position. Selection (P) : Park (locking and immobilisation of the vehicle). Selection (R) : Reverse gear. Selection (N) : Neutral. Selection (D) : Drive (Use of the four gears in their autoadaptive automatic function) Selection (M) : Manual (M + M -) allowing the driver to select gears by pulling and pushing the gear lever. In position M, selection is by an electronic sensor located close to the gear lever. The variation of flux necessary to the movement of the sensor cells is obtained by a magnet located on the lever itself. This enables the change of status.

CLUTCH GEARBOX DRIVESHAFTS

B2CP3DKD

166

4 HP 20 GEARBOX CONTROLS
Engines : XFX - 4HX Selection control (continued).

C5 - All Types

In position M, selection is by an electronic sensor located close to the gear lever. The variation of flux necessary to the movement of the sensor cells is obtained by a magnet located on the lever itself. This enables the change of status. The information is transmitted to the gearbox ECU. Two switches placed on the gear control gate permit the driver to choose one of the following three driving programmes: - Normal : The normal programme operates in the absence of the other two (Eco law, autoadaptative mode). - Sport : Permits a more dynamic, sporty performance. - Snow : Facilitates starting and adhesion on slippery surfaces. To return to the normal programme, press a second time on the sport switch or snow switch. Only when the selector is in position (P) or (N) can the engine be started. - (1) Control linkage with ball-joint. - (2) Automatic adjustment (Push-button c , pressed in to lock the control adjustment, springs out for the adjustment to be made). - (3) Cable sleeve stop. The automatic gearbox is controlled by cable.

B3CP3DLC

167

CLUTCH GEARBOX DRIVESHAFTS

SYNERGIE

RECOMMENDATIONS - PRECAUTIONS (AL 4 AUTOMATIC GEARBOX)


Engine : RFN (Synergie) Gear control is by a cable linked to the selection lever located on the dashboard. The gear selection control has 5 positions : P Park (immobilisation of the vehicle, whatever the slope). R Reverse gear. N Neutral. D Drive (autoadaptative mode, eco-law) M Manual mode (M+, M-). The vehicle can only be started when the selection lever is in position P or N. Shift-Lock The shift-lock is a system which locks the gear selection lever in position P. To unlock the gear selection lever from position P, switch on the ignition and press the brake pedal. During a repair, the shift-lock can be unlocked by pressing the locking finger a (see corresponding operation).

CLUTCH GEARBOX DRIVESHAFTS

B2CP3CFD

168

DRIVESHAFTS - GEARBOX
Tightening torques (m.daN) Vehicles Gearbox BE4/5 C5 SYNERGIE ML/5 AL4 4 HP20 Engines 6FZ - RFN - RLZ RHY XFX RHZ - 4HX 6FZ - RFN - RHZ XFX - 4HX Driveshaft bearing Driveshaft nut

SYNERGIE - C5
Gearbox oil seal mandrels Right 7114-T.W 9017-T.C Left 7114-T.X 5701-T.A 0338 H1 0338 H2 8010-T.J 8010-T.K2 Tool kit 7116-T 9017-T 0338 8010-T

2 0.2

32.5 1.5 0338 J1 0338 J3 8010-T.D 8010-T.K1

C5 CITRON SYNERGIE 169

Steel Aluminium

9 0.5 10 0.5

CLUTCH GEARBOX DRIVESHAFTS

Tightening torques (m.daN) of the wheel bolts

C5 - All Types
Measuring front height The measurement of the front dimension H1 is between ground level and the measuring zone on the front subframe (to the rear of the front yokes fixing the suspension arm).

AXLE GEOMETRY
Measuring rear height

B3BP166D

B3BP168D

L1 (mm) Theoretical dimension between the level of the front subframe and the wheel axis. 140

L2 (mm) Theoretical dimension between the measuring zone on the crossmember support and the wheel axis. 73 170

ESSIEUX SUSPENSION DIRECTION

AXLE GEOMETRY
Front axle Vhicle Tracking Adjustable All Types 0 to - 3 mm 0 to - 0 27' 3 03' 30' Castor Camber Non adjustable 0 30' 12 56' 30' King pin inclination Tracking Adjustable 5.4 1.3 mm 0 49 0 12 Rear axle

C5 - All Types

Camber Non adjustable - 1 20'

NOTE A < B = Positive figure : A > B = Negative figure :


B3CP02UC

+= =

TOE-IN TOE-OUT

171

AXLES SUSPENSION STEERING

AXLES SUSPENSION STEERING

C5 - All Types

FRONT AXLE
Tightening torques m.daN. (1) Suspension leg upper fixing (2) Suspension leg fixing on bodyshell (3) Anti-roll bar link rod upper fixing (4) Anti-roll bar link rod upper fixing (5) Ball-joint fixing (6) Ball-joint fixing on pivot (7) Suspension leg upper fixing on pivot (8) Hub nut (9) Wheel fixing (10) Arm front fixing (11) Arm rear fixing (12) Anti-roll bar bearing fixing on subframe Stabiliser bar fixing on subframe Anti-roll bar Engines All types (except ES9J4) ES9J4 Diameter (mm) 23.5 24.5 Colour ref. Yellow White 7 0.7 4.3 0.6 6.4 0.6 6.4 0.6 4.5 0.4 25 2.5 5.4 0.5 32.5 2.6 91 13 1.3 8 0.8 4.2 0.6 6.6 0.6

B3CP05VP

B3CP05WD

NOTE : The geometry specifications are given with the suspension specifications. 172

REAR AXLE
Tightening torques m.daN. (1) (2) (3) (4) (5) (6) (7) Anti-roll bar fixing Rear rubber mounting fixing on bodyshell Rear subframe fixing Front subframe fixing on bodyshell Suspension shaft fixing Hub nut Wheel fixing

C5 - All Types

13.1 1.4 8 1.2 11.5 1.1 11.5 1.1 14.9 1.3 25 2.5 91

NOTE : (3) and (4) Face and threads not greased. Anti-roll bar Engines All types (except ES9J4) ES9J4 All types estates Diameter (mm) 21.5 22 Colour ref. Blue Yellow

NOTE : The geometry specifications are given with the suspension specifications.
B3DP08BD B3DP08CD

173

AXLES SUSPENSION STEERING

AXLES SUSPENSION STEERING

C5 - All Types

SUSPENSION
Front suspension

Tightening torques m.daN. (10) Arm front fixing 11) Arm rear fixing (12) Anti-roll bar bearing fixing on subframe 13 1.3 8 0.8 4.2 0.6

Hydractive 3+ hydraulic suspension (power steering) Suspension piston diameter Anti-roll bar diameter Anti-roll bar colour reference Suspension leg. Bump stop, height
B3CP05WD B3BP167D

= 35 mm. = 23,5 mm. = Yellow.

"A" = 97 mm.

174

SUSPENSION
Rear suspension Tightening torques m.daN. (13) Subframe rear fixing (14) Rear rubber mounting fixing on bodyshell (15) Anti-roll bar fixing (16) Front fixing of subframe on bodyshell NOTE : (13) and (16) Face and threads greased. (17)Arm shaft fixing (18) Hub nut (19) Wheel fixing Stabiliser bar fixing on subframe Hydractive 3+ hydraulic suspension (power steering) Suspension piston diameter = 37 mm. Anti-roll bar diameter - Saloon = 21.5 mm - Break = 22 mm. Anti-roll bar colour reference - Saloon = Blue - Estate = Green
B3DP08ND B3DP08PD

11.5 1.1 8 1.2 13.1 1.4 11.5 1.1 14.9 1.3 25 2.5 91 6.6 0.6

175

AXLES SUSPENSION STEERING

AXLES SUSPENSION STEERING

C5 - All Types

SUSPENSION

Height control

Tightening torques m.daN. (20) Collars 0.6

B3CP06TD

176

AXLE GEOMETRY
Front axle Vhicle Tracking (Adjustable ) All Types 0 to - 3 mm 0 to - 0 27' 3 03' 30' Castor Camber (Non adjustable) 0 30' 12 56' 30' King pin inclination Tracking (Non adjustable) 5.4 1.3 mm 0 49 0 12 Rear axle

C5 - All Types

Camber (Non adjustable) - 1 20'

NOTE A < B = Positive figure : A > B = Negative figure :


B3CP02UC

+= =

TOE-IN TOE-OUT

177

AXLES SUSPENSION STEERING

AXLES SUSPENSION STEERING

C5 - All Types

SPECIFICATIONS OF POWER-ASSISTED STEERING


Engines : 6FZ - RFN - XFX - RHY - RHS - RHZ - 4HX Tightening torques m.daN.

(1) Steering wheel fixing (2) Column fixing on mounting (3) Column fixing on mounting (4) Cardan fixing (5) Ball-joint fixing on pivot (6) Link rod lock nut (7) Valve fixing on cover (8) Piping fixing on ram (9) Mechanism fixing on subframe (10) Steering rack ball-joint

2 0,3 2.3 0.4 2.3 0.2 2.3 0.3 3.5 0.6 6 0,4 2.3 0.1 0.8 0.8 8 0.9 9 0.9

Quantity of oil = 4.3 litres Quality of oil = TOTAL FLUIDE LDS

B3EP124D

B3EP125D

178

SPECIFICATIONS OF POWER-ASSISTED STEERING


Engines : 6FZ - RFN - RLZ - XFX - RHY - RHS - RHZ - 4HX Engines 6FZ-RFN RHY-RHS-RHZ XFX 4HX Engine 6FZ-RFN RHY-RHS-RHZ-4HX XFX Steering rack travel (mm) 2x83 2x74 Supplier ZF SAGINAW Flow type Falling Constant Number of teeth Pinion 9 Rack 33 Number of turns of the wheel 3.3 3 Regulation pressure 100 bars Steering ratio

C5 - All Types
Angle of lock Inner 39.74 34.29 Outer 35.65 31.58 Pulley diameter 129 mm

50.4/1

Tightening torques m.daN Engine types EW-DW (12) Screw (13) Screw (14) Screw 2.2 0.3

ES9J4 2.5 0.6

Engine XFX : A converter, integral with the valve, modulates the assistance according to the vehicle speed. Length of steering rods (Adjustment) between ball-joints = 362 mm. Power-assisted steering hydraulic circuit. The oil supplies both the steering circuit and the suspension circuit.

B3EP127D

Petrol engine : A power-assisted steering pressure switch is installed on the hydraulic piping, between the high pressure pump and the steering valve. 179

AXLES SUSPENSION STEERING

AXLES SUSPENSION STEERING

SYNERGIE
Reference height

AXLE GEOMETRIES

NOTE A < B = Positive figure : A > B = Negative figure : Conditions for adjusting the heights (Tyre pressures correctly set) Frontt H1 158 161 166 Heights (mm) Tyres 195/70R 14 195/65R 15 205/65R 15 Rear H2 163 166 171 Camber King pin inclination 0 30 1128 40 -1 30 Tracking (Toe-in/toe-out)

+ = - =

TOE-IN TOE-OUT

B3BP051D

Front 0 mm 330 to 30 +08 to +025 +1 to +3

Rear

Castor angle max. (left-right difference : 30)

The reference heights must be checked between the jacking points and the ground. B3BP051D

180

FRONT AXLE

SYNERGIE

B3CP04PD

B3CP04QD

181

AXLES SUSPENSION STEERING

AXLES SUSPENSION STEERING

SYNERGIE

FRONT AXLE
Evolution : Tightening torques on front subframe 28/05/1999 #

(1) Fixing screw (front). (2) Fixing screw (rear).

Tightening torque. Old fitting. Tighten the screw (1) to 13.5 m.daN. Tighten the screw (2) to 13.5 m.daN. New fitting. Tighten the screw (1) to 10.7 m.daN. Tighten the screw (2) to 10.7 m.daN. NOTE : Replacement Parts markets the old as well as the new components.

B3CP055D

182

REAR AXLE

SYNERGIE

B3DP06QD

183

AXLES SUSPENSION STEERING

AXLES SUSPENSION STEERING

SYNERGIE

SUSPENSION
All Types Ft Rr Ft Rr Without air-con With air-con Ft 2 Grey = 1 Yellow Rr 3 Yellow F 23 F 254 25 30 1 Grey + 1 Yellow

Shock absorber (ref.) Anti-roll bar (mm)

Spring (ref.)

184

STEERING
Steering All Types Power-assisted Steering rack travel (mm) 152 Number of teeth Pinion 9 Steering rack 33 Number of turns of the steering wheel 2.98

SYNERGIE
Steering ratio 15.75

B3EP09ZD

185

AXLES SUSPENSION STEERING

BRAKES

C5 - All Types
1.8i 16V Engine type Master cylinder Master-vac mm Ft Caliper/piston makes Brake disc Non-ventilated Ventilated 266 22/20 ABEX 949/1 6FZ

BRAKE SPECIFICATIONS
2.0i 16V RFN 22.2 (Valve type) 254 BOSCH ZO 54/55 BIR 54 BOSCH ZO 57/56 BIR 57 283 26/24 ABEX 949/1 PSA 32 (double piston) 276 14/12 ABEX or TEXTAR 949/1 or T 4110 186 BOSCH ZO 57/28BIR 57 288 28/26 TEXTAR T 4110 2.0 HPi RLZ 3.0i V6 XFX

Disc thickness/min. thickness Brake pad grade mm Rr Cylinder or caliper Drum / max. Brake disc Non-ventilated

Disc thickness/min. thickness Make Brake lining grade

BRAKE SPECIFICATIONS
2.0 HDi Engine type Master cylinder Master-vac mm Ft Caliper/piston makes Brake disc Non-ventilated Ventilated 283 26/24 TEXTAR T 4110 PSA - 32 (Double piston) 276 14/12 TEXTAR or ABEX T 4110 or 949/1 187 288 28/26 BOSCH ZO 57/26 BIR 57 RHY RHS 22.2 (Valve type) 254 BOSCH ZO 57/28 BIR 57 RHZ 2.2 HDi 4HX BRAKES

Disc thickness/min. thickness Brake pad grade mm Rr Cylinder or caliper Drum / max. Brake disc Non-ventilated

Disc thickness/min. thickness Make Brake lining grade

C5 - All Types
Braking circuit

BRAKE SPECIFICATIONS
Braking system specifications

- Braking circuit at X. BRAKES


B3FP12WD

- Front brakes with ventilated discs. - Rear brakes with non-ventilated discs. - Handbrake lever controlling cables acting on the front wheels. - The compensator and main brake limiter functions are assured by the ABS EBD system fitted as standard at the factory on all versions. NOTE : EBD = Electronic Brakeforce Distribution

188

BRAKE SPECIFICATIONS
Braking circuit diagram

C5 - All Types

(a) Hydraulic circuit. (b) Electrical circuit. (1) Master cylinder in tandem. (2) Braking servo. (3) Brake caliper. (4) Hub equipped with a bearing with an integral magnetic wheel (48 pairs of poles). (5) Wheel sensor. (6) Brake fluid level sensor. (7) Hydraulic block plus ECU. (8) Stoplamp switch. (9) Instrument panel. (10) Diagnostic socket. (11) Built-in systems interface (BSI).

B3GP02HP

189

BRAKES

C5 - All Types
(7) Hydraulic block Elements Electronic ECU. BRAKES
B3FP12XC

BRAKE SPECIFICATIONS
Ref. 7 Supplier ITT - A BASR MK.60 Part No. ABS MK.60 Observations 47 way connector Alone on the hydraulic block. 2 way black connector. The sensors are inductive-type. Mounted on the pivot. Non-adjustable airgap: 0.2 to 1.5 mm. Tightening torque: 0.8 0.2 m.daN 2 way black connector. The sensors are inductive-type. Mounted on the brake caliper support. Non-adjustable airgap: 0.15 to 1.6 mm. Tightening torque: 0.8 0.2 m.daN Hub equipped with a bearing with an integral magnetic wheel (48 pairs of poles) ABS MK.60 96 371 711 80 BASK MK.60 96 371 712 80 Installed on the front LH wheelarch. 4 adjustment channels.

Front wheel sensor.

ITT - A

96 332 952 80

Rear wheel sensor.

96 332 954 80

Hub bearing. Hydraulic block.

SNR

TEVES

190

BRAKE SPECIFICATIONS
Brake pedal carriage Front brake

C5 - All Types
Rear brake

B3FP130C

B3FP12YC

B3FP12ZC

Tightening torques (m.daN). (15) Fixing on bodyshell (16) Servo fixing 1.8 0.25. 2.1 0.1. (12) Caliper fixing on pivot (13) Yoke fixing on caliper 191 12 1.8 3.1 0.1 (14) Rear caliper fixing on suspension arm 7 0.7

BRAKES

C5 - All Types

HANDBRAKE (Adjustment)
Adjustment - Remove the rear ashtray from the handbrake console. - (1) Nut for adjusting the tension of the handbrake cables. - Raise and support the vehicle with the front wheels hanging free. - Check the correct routing of the brake cables under the vehicle. - Apply and release the handbrake 10 times. - Set the handbrake to the 5th notch. - Tighten the nut (1) until the front brakes are applied. - Pull the handbrake lever vigorously 4 to 5 times. - Set the handbrake to the 5th notch. - Check that the front brakes are applied. - With the handbrake released, check that the wheels can be turned freely by hand. - Lower the vehicle. - Refit the rear ashtray to the handbrake console.

BRAKES
B3FP12JD

192

BLEEDING AND FILLING THE BRAKING SYSTEM


Tools. [1] Generic bleeding apparatus [2] PROXIA station [3] LEXIA station : "LURO" or similar. : 4165-T. : 4171-T. Bleeding, filling. Draining the brake fluid reservoir. - Drain the brake fluid reservoir (1) to the maximum (if necessary, use a clean syringe). - Disconnect the connector (3). - Uncouple the pipe (2). - Remove the reservoir (1) by separating the lugs a from the shaft (4). - Empty the brake fluid reservoir (1). - Clean the brake fluid reservoir (1). Remove : - The brake fluid reservoir (1). - The shaft (4). - Couple the pipe (2). - Reconnect the connector (3).

C5 - All Types

B3FP139C

B3FP13AC

193

BRAKES

C5 - All Types

BLEEDING AND FILLING THE BRAKING SYSTEM


Bleeding, filling (continued). Filling the braking system. WARNING : Use only those hydraulic fluids that are approved and recommended. - Fill the brake fluid reservoir (1). Bleeding the braking system. WARNING: During the bleeding operation, take care to maintain the level of brake fluid in the reservoir and to top it up, using only brake fluid that is clean and clear. Bleeding the primary circuit. WARNING: The ABS should not be active during the bleeding operation. - Front brake caliper: Bleed screw (5). - Rear brake caliper: Bleed screw (6). - Bleed each wheel cylinder, proceeding in the following order : Front LH wheel. Front RH wheel. Rear LH wheel. Rear RH wheel.

BRAKES

B3FP13BC AB3FP13CC

194

BLEEDING AND FILLING THE BRAKING SYSTEM


Bleeding, filling (continued).

C5 - All Types

B3FP13DC

With the bleeding apparatus - Connect the bleeding apparatus [1] on the brake fluid reservoir (1). - Adjust the apparatus pressure to 2 Bars. For each circuit : - Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container. - Open the bleed screw, wait until the fluid is flowing out without air bubbles. - Close the bleed screw. - Remove the bleeding apparatus [1]. - Check the brake fluid level (Should be between DANGER level and MAXI level). - Fill if necessary with the approved and recommended synthetic brake fluid. Without the bleeding apparatus. NOTE : Two operators are necessary. For each circuit : - Apply the brake pedal to place the circuit under pressure. - Connect a transparent tube onto the bleed screw, submerge the other end of the tube in a clean container. - Open the bleed screw, wait until the fluid is flowing out without air bubbles. - Close the bleed screw. - Remove the tool [1]. NOTE : Recommence the process a second time if that is necessary. - Check the brake fluid level, (Should be between DANGER level and MAXI level). - Fill if necessary with the approved and recommended synthetic brake fluid. 195

BRAKES

BLEEDING AND FILLING THE BRAKING SYSTEM


Bleeding, filling (continued). Bleeding the secondary circuit. BRAKES NOTE : The bleeding apparatus is connected on the brake reservoir. - Use LEXIA or PROXIA diagnostic tools. Select the menu corresponding to the vehicle : - ABS menu. - ESP menu. - Follow the instructions on the diagnostic tool. - At the end of the bleeding process, check and top up, if necessary, the brake fluid level. - Check that the brake pedal travel has not been lengthened, otherwise repeat the bleeding procedure. - Remove the tools.

196

BRAKE SPECIFICATIONS
2 0 HDi Master cylinder mm Ft Disc Disc thickness Minimum disc thickness Brake pad grade Cylinder or caliper mm Rr Drum Disc Max./ min. thickness Make Brake lining grade Compensator cut-off in Bars DON 7124 Front brake 65 Rear brake 65 197 BENDIX FN 36 20.6 255 295 10/8 Master-vac Caliper/piston makes 279 GIRLING C57 57 281 (Ventilated) 26 24 GALFER 3314 36 23.8 2.0i 16V

SYNERGIE

203 + 230 (Tandem) BRAKES GALFER 36212 Front brake 85 - Rear brake 85

SYNERGIE

BRAKES
Manual adjustment of the compensator

- Set the vehicle at reference height (see page 180). ESSENTIAL : Never alter the position of the upper nut (1). - Refit the flanged nut (2). - Fit the tool 8204-T. Drum At shim A At shim B Yellow Red Disc Blue BRAKES
B3FP10TC

- Adjust the nut (3) to allow the free passage, without play, of the red shim (B), without moving the lever (4) downwards. - Tighten the lock nut (5) without modifying the adjustment. - Remove the threaded rod at C. - Tighten the flanged nut (2) over the nut (3).

198

BRAKES (continued)

SYNERGIE

Checks and hydraulic adjustment of the compensator - Use the brake pressure checking equipment 4104-T, connect diagonally and bleed: bleed screw : Caliper 8x125 - Wheel cylinder 7x100. - Set the vehicle at setting height. BRAKES - Pressure chart : Engine : 2 0 HDi Disc Front 40 65 135 Drum Rear 40 65 86 Front 50 85 135 Engine : 2.0i 16V Disc Rear 50 85 100

- If the pressures are not correct, adjust as follows : - Refit the nut (1). - Adjust using the nut (2) to obtain the braking pressure. - Tighten the lock nut (3). - Hold the threaded rod (4). - Tighten the flanged nut (1) over the nut (2).
B3FP10UC

199

SYNERGIE

HANDBRAKE

BRAKES
B3FP10VC B3FP10WC B3FP10XC

Slacken the cables using the nut (1). - Remove the blanking plug from hole A. - Position hole A opposite the toothed wheel (adjusting mechanism). - Turn the toothed wheel using a flat screwdriver until the disc locks. - LH side upwards. - RH side downwards. - Unlock the disc by turning in the opposite direction by 6 notches.

- Position the blade B of the blanking plug perpendicular to the line passing through the centre of the disc and the centre of the hole. - Tighten nut (1) to obtain a handbrake lever travel of 4 to 5 notches. - Tighten the lock nut (2).

200

HYDRAULIC SPECIFICATIONS
Location of components (A) High pressure hydraulic circuit. (B) Low pressure hydraulic circuit. (C) Electric circuit. (21) Built-in Hydro-electronic Interface (BHI). (22) Front slimline sphere. (23) Front suspension cylinder. (24) Rear slimline sphere. (25) Rear suspension cylinder. (26) Front hydractive 3+ regulator accumulator. (27) Front hydractive 3+ regulator. (28) Rear hydractive 3+ regulator accumulator. (29) Rear hydractive 3+ regulator (30) Front height sensor. (31) Rear height sensor. (32) LDS fluid reservoir . (33) Suspension switch.

C5 - All Types

B4CP01FP

201

HYDRAULIC SYSTEM

C5 - All Types

HYDRAULIC SPECIFICATIONS
Reservoir

Reference "d" "e" "f" "c"

Function Induction

Component (BHI) Built-in Hydro-electronic Interface Power steering pump (BHI) Built-in Hydro-electronic Interface

Return

Power steering pump Suspension cylinders

HYDRAULIC SYSTEM
B4BP01BC

Synthetic fluid TOTAL FLUIDE LDS. Capacity of the circuit 4.3 litres.

202

HYDRAULIC SPECIFICATIONS
Built-in Hydro-electronic Interface (BHI).

C5 - All Types

Reference (36)

Component Electric motor Hydraulic unit comprising : Pump with 5 axial pistons - Anti-pulse hydropneumatic accumulator A safety valve Electronic control unit 4 electrovalves: Front suspension inlet Rear suspension inlet Front suspension exhaust Rear suspension exhaust

Specifications 2350 150 rpm Throughput = 0,7 l/min at 2300 rpm Diameters of the pistons = 6,35 mm Safety valve rating = 180 Bars HYDRAULIC SYSTEM

(35)

(34)

(37)

The vehicles anti-sink function is assured by the exhaust electrovalves

B3BP169P

203

C5 - All Types
Hydractive 3+ regulator

HYDRAULIC SPECIFICATIONS
Hydraulic unions

HYDRAULIC SYSTEM

B4BP01CD

B4DP003D

(40) (39) (38) (41)

Slimline sphere. Hydractive regulator. Electrovalve. Depressurisation screw.

Reference G H J 204

Tube diameter (mm) 3,5 6,35 10

Tightening torque m.daN 1,5 0,3 2,5 0,5

SPECIFICATION - IDENTIFICATION : SUSPENSION SPHERES


Special features Identification. - Fitting of new slimline spheres with multilayer membranes, stone grey in colour. - It is forbidden to recharge or overhaul this type of sphere. - The number marked on the suspension sphere is the reference no. of the component and not the Part No. - The two-figure number marked on the suspension sphere indicates the initial inflation pressure value. Example : Suspension sphere marking 96 420 906 80 Batch of steel AG2 Day of manufacture 066 Year of manufacture 0 Time of manufacture 13h59

C5 - All Types

57

- The pressure value of this type of suspension sphere is given merely as a guide. - When checking, the value read could be higher than the nominal value. NOTE : Suspension cylinders on the same axle should be equipped with the same type of membranes. Tightening torques for these spheres : 2,7 0,5 m.daN.

205

HYDRAULIC SYSTEM

Pressure rating (Bars)

C5 - All Types

SPECIFICATION - IDENTIFICATION : SUSPENSION SPHERES

(1) Front suspension sphere. (2) Rear suspension sphere. HYDRAULIC SYSTEM
B4BP01DD

(3) Front hydractive 3+ regulator accumulator. (4) Rear hydractive 3+ regulator accumulator.

206

SPECIFICATION - IDENTIFICATION : SUSPENSION SPHERES


Hydractive 3 suspension Front suspension sphere (1) WARNING : The number marked on the suspension sphere is the reference no. of the component and not the Part No. Engines 6FZ RHY-RHS-RHZ All types Suspension sphere marking 96 420 906 80 96 420 907 80 96 420 905 80 Volume(cc) 385 Rear suspension sphere (2) 385 Hydractive 3+ suspension Front suspension sphere (1) RFN-RLZ XFX-4HX All types Hydractive regulator Front (3) Rear (4) 96 420 908 80 96 420 909 80 96 422 091 80 Suspension sphere marking 96 420 898 80 96 373 373 80 207 385 Rear suspension sphere (2) 385 Hydractive regulator accumulator Volume (cc) 385 Pressure (Bars) 62 45 25 1.4/0.94 44 52 0.9/0.48 31 0.7/0.48 HYDRAULIC SYSTEM Pressure(Bars) 57 Diameter of damper hole (mm) 1.9/1.3 1.75/1.3

C5
Vehicle Engine Gearbox

STARTER MOTORS
Petrol engines Reference Class Climate H Manual U 3 T C V 1.8i 16V U C5 Automatic V 4 3 4 VC H T C VC H U 2.0HPi Manual V 4 3 T C VC

ELECTRICAL SYSTEM

CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 212 208

STARTER MOTORS
Petrol engines Vehicle Engine Gearbox Reference U Manual V 2.0i 16V U C5 Automatic V 4 3 4 Class 3

C5
Climate H T C VC H T C VC H T C VC ELECTRICAL SYSTEM

2.0i 24S

All Types

R2

CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 212 209

C5
Vehicle Engine Gearbox

STARTER MOTORS
Diesel engines Reference Y Z1 Manual Y C5 2.0 HDi (RHS-RHZ) Automatic Z3 6+ Z1 6 5 Class 5 6 Climate H T C VC H T C VC H T C VC

2.0 HDi (RHY)

ELECTRICAL SYSTEM

CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 212 210

STARTER MOTORS
Diesel engines Vehicle Engine Gearbox Reference Y Manual Z2 C5 2.2 HDi Y Automatic Z2 6+ Class

C5
Climate H T C VC H T C VC

CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 212 211

ELECTRICAL SYSTEM

C5
Vehicle Engine Reference

STARTER MOTORS
Alternator reference Make VALEO Petrol 1.8i 16V 2.0i 16V 2.0 Hpi 3.0i 24S C5 X Y 2.0 HDi 2.2 HDi Z1 Z2 Z3 D8 R 27 V R2 M000T 85 381 D6 RA 661 Diesel D6 RA 109 D7 R 26 D7 R 27 A001 236 080 M001 T8 0381 M001 T8 0481 A001 111 562F U D6 RA 72 M000T 82 081 EOAL 098390 MELCO BOSCH

Table of classes of starter motors CLASS Torque C Maximum current for a speed of 1200 rpm CLASS 2 5.5 Nm I 275 A CLASS 3 6 Nm I 300 A 212 CLASS 4 10 Nm I 430 A CLASS 5 11.5 Nm I 470 A CLASS 6 11.5 Nm I 500 A

ELECTRICAL SYSTEM

STARTER MOTORS
Petrol engines Vehicle Engine Gearbox Reference U Manual V 2.0i 16V U Automatic V SYNERGIE Diesel engines Y Z1 2.0 Hdi 2.0 16V HDi Manual Y Z1 5 6 5 6 4 3 4 Class 3

SYNERGIE
Climate H T C VC H T C VC H T C VC H T C VC

CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 214 213

ELECTRICAL SYSTEM

SYNERGIE
Vehicle Engine Reference

STARTER MOTORS
Alternator reference Make VALEO Petrol 2.0I 16V U V Diesel 2.0 HDi 2.0 16V HDi Y Z1 D7 R 26 D7 R 27 M001 T8 5381 D6 RA 72 M000T8 2081 M000 T8 2081 E0AL 098 390 MELCO BOSCH

SYNERGIE

Table of classes of starter motors CLASS Torque C Maximum current for a speed of 1200 rpm CLASS 2 5.5 Nm I 275 A CLASS 3 6 Nm I 300 A 214 CLASS 4 10 Nm I 430 A CLASS 5 11.5 Nm I 470 A CLASS 6 11.5 Nm I 500 A

ELECTRICAL SYSTEM

ALTERNATORS
Class of alternator Vehicle Model Gearbox Without aircon Without Cold Pack With Cold Pack Base With GPS Base With GPS 9 With aircon Without Cold Pack With Cold Pack Base With GPS Base With GPS 12 12 12 12 9 9 9 9 12 Automatic C5 Manual 2.0i 16V 12 Automatic 12 9 CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 217 215 12 12 9 9 9 9 12 12 9 9 9 12 9 12 12 9 12

C5
Climate

Manual 1.8i 16V

12

ELECTRICAL SYSTEM

H T C VC H T C VC H T C VC H T C VC

C5
Vehicle Model Gearbox

ALTERNATORS
Class of alternator Without aircon With aircon Without Cold Pack With Cold Pack Without Cold Pack With Cold Pack Base Manual Automatic With GPS Base With GPS Base With GPS Base With GPS H T C VC H T C VC H T C VC Climate

3.0i 24V

15

15

15

15

C5

2.0HDi 2.2 HDi

Manual

15

15

15

15

15

15

15

15

2.0 HDi

Automatic

15

15

15

15

15

15

15

15

ELECTRICAL SYSTEM

CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page 217 216

ALTERNATORS
Vehicle Engine 1.8i 16V 2.0i 16V 2.0 HPi 3.0i 24S C5 2.0 HDi All types 15 2.0 HDi (1) 2.2.HDi Gearbox Class 9 12 A14 VI 25+ SG 15 S0 16 SG 15 S0 21 A14 VI 27+ SG 15 S0 18 SG 15 S0 22 A14 VI 41+ VALEO A 13 VI 204+ SG 10 B0 21 Alternator reference Make MELCO A002 TB 4891 A003 TA 0891 A004 TF 0091

C5

BOSCH

A 120 51 611

(1) = With particle filter (FAP)

217

ELECTRICAL SYSTEM

SYNERGIE
Vehicle Model Gearbox Without aircon 8 Manual

ALTERNATORS
Class of alternator With aircon 12 9 Climate H T C VC H T C VC H T C VC

2.0i 16V Synergie Automatic

8 9

15 12

2.0 HDi 2.0 HDi 16V

Manual

15

ELECTRICAL SYSTEM

CLIMATE : H (Hot), T (Temperate), C (Cold), VC (Very cold) - NOTE : See alternator references by class, table on page : 219 218

ALTERNATORS
Vehicle Model Gearbox Class 8 9 All types 2.0 HDi 2.0 16V HDi 12 A14 VI 40+ SG 15 S0 17 SG 15 S0 18 SG 15 S0 22 A14 VI 41+ VALEO A13 VI 2A6 SG 8 B0 21 A13 VI 277+ SG 10 B0 22 Alternator reference Make MELCO A005 TA 6391

SYNERGIE

BOSCH

2.0i 16V Synergie

A003 TB 2691

15

219

ELECTRICAL SYSTEM

ALL TYPES

CHARGING CIRCUIT - ALTERNATOR WITH MONO-FUNCTION REGULATOR


CHECKING THE ALTERNATOR OUTPUT Connect as shown in the diagram opposite, using an ammeter (A), a voltmeter (V), and a rheostat (R) or a Volt/Ammeter/Rheostat combination. Referring to the vehicles equipment specification (see table opposite), adjust the engine speed and rheostat charge to obtain U=13.5V. Read the voltage. Reminder : The excitation energising current will flow through the warning lamp; check that the warning lamp comes on when the ignition is switched on. It should go out when the engine has started (accelerate slightly). CHECKING THE VOLTAGE REGULATOR Set the rheostat to zero and disconnect all the electrical consumers. Display 5000 alternator rpm. If U alternator is > 14.7 V, the regulator is faulty. Note : These tests should be performed with the engine hot and the battery fully charged. 9 62 A 76 A 83 A Output under 13.5 V Intensity (A) / Alternator speed
Speed Class

2000 rpm 29 A

3000 rpm 39 A

4000 rpm 43 A

42 A

54 A

59 A

49 A

62 A

68 A

12

72 A

90 A

100 A

ELECTRICAL SYSTEM

15
D1AP01SC

99 A

128 A

140 A

220

PRE-HEATING AND STARTING CIRCUITS


Vehicles Engines Pre-heater plugs Pre-heater control unit

C5 - SYNERGIE
Pre-post-heating (Pre-heating time at 20C)

C5 Synergie

2.0 HDI 2.0 16V HDI 2.2 HDI

CHAMPION CH 170

CARTIER 51299011A NAGARES 960411-P CARTIER 51299011A NAGARES 960411-P

Piloted by the diesel injection ECU

BERU A0100 226 344

Preheater plug resistance : 0.4

R 0.6
221

ELECTRICAL SYSTEM

C5 - SYNERGIE
Vehicle Engine version Date

AIR CONDITIONING R 134 a (HFC)


Refrigerant refill ( 25 gr) Compressor Variable capacity Oil quantity cc Oil reference

C5

1.8i 16V-2.0i 16V 2.0 HPi 3.0i 24S 16V 2.2 HDi 2.0 HPi

650 11/2000 : + 0 - 50 gr

SD 7 V16

SD 7 V16

SP 10

DELPHI V5 (1)

265 15

PLANETELF 488

SYNERGIE

All Types

06/94 >

1000 50 gr

SD 7 V16

135

SP 10

AIR CONDITIONING

(1) HARRISON Division.

222

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)


Click-fit union removal/fitting tool Vehicle Inch Ring colour

SYNERGIE
Tool kit 4164-T

SYNERGIE

All Types

5/8

Black

8005-T.A.

C5HP073C

Tightening torques (m.daN). Unions Aircon compressor fixings. IMPERATIVE : Tighten the front part of the compressor (timing belt end), before tightening the rear part of the compressor. Pipes M 06 M 08 M 10 Steel/Steel 1.7 0.3 3.8 0.3 4 0.3 Aluminium/Steel 1.3 0.3 2 0.2 2.5 0.3

REMINDER : Refilling the air conditioning system should be done through the LOW PRESSURE valve whenever possible. NOTE : The diameters of the High Pressure and Low Pressure valves are different, to avoid mixing them up. 223

AIR CONDITIONING

AIR CONDITIONING

C5 - SYNERGIE
Vehicle C5

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)


Summary table for presence of pollen filter Equipment Aircon all types Without aircon Base aircon RPO no. Presence of filter YES NO NO # 8148 Automatic aircon 8148 # 8421 8421 # Do not fit YES (Behr) YES if Exclusive NO if X and SX Water ingress Body modification 2 blowers 1 blower Observations

SYNERGIE (*)

(*) = The (three) pollen filters on SYNERGIE are located at the base of the windscreen. 224

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)


Pollen filter

C5

Remove : - The trim (1) under the dashboard (drivers side). - The cover (2).

Unclip at a and pull out the pollen filter (3). Remove the pollen filter (3).

C5FP0C5C

C5FP0C6D

225

AIR CONDITIONING

AIR CONDITIONING

C5

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)


Drying cartridge Tools [1] Filling and recycling station [2] TORX adaptor [3] After Sales kit MULLER - ECOTECHNICS 70 FACOM (Bottle /skirt / bottle nozzle /grease / compressor oil)

Reminder : All repairs on an aircon circuit require the aircon circuit to be drained. After carrying out the dismantling operations necessary to gain access to the condenser, proceed to clean the area of the skirt (8) of the reservoir (6) using a cloth, then replace the dryer reservoir (6). Removing the plastic bracket holding the reservoir (6) : - Remove the screw (3) (Torx 20), from the bracket assembly/plastic counter-bracket (4) and (5). - Remove the counter-bracket (5).(Rotate it round the hinge in a clockwise direction). - Disengage the bracket from the harness (1) (Rotate it round the reservoir (6) anti-clockwise). - Remove the bracket (5) from the reservoir body (6). Unscrewing the reservoir (6). - Unscrew the reservoir (6) using the tool [2].

C5HP16EC

226

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)


Condenser with integral reservoir (continued)

C5

Removing the reservoir (6) from the base (8). WARNING : This operation requires the greatest care, the base (8) should be kept clean prior to fitting the new reservoir. - Remove the reservoir (6) and the protection skirt (7), avoiding WITHOUT FAIL any contact or collision with other items under the bonnet (Risk of impurities entering the base (8)). - Check before refitting the reservoir (6) that the base (8) is clean. (If it is not, clean in and around the base (8) with a paper cloth.) Preparing the new dryer reservoir - Remove the black plastic protection cap from the reservoir neck (6) , leaving in place the green protection at the other end, in order to keep the new reservoir (6) sealed when mounting it in the base (8) of the condenser. - Use the grease sachet in the replacement kit, to lubricate the threads of the reservoir. - Use the oil sachet in the replacement kit, to lubricate the two O-ring seals of the reservoir (6). - Position the reservoir (6), with its new protection skirt (7) from the replacement kit, and engage the threads of the reservoir (6) in the base (8). - Check that the downward edge of the skirt (7), covers the base (8) all around it.
C5HP16EC

227

AIR CONDITIONING

AIR CONDITIONING

C5

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)


Condenser with integral reservoir (continued)

WARNING : The reservoir (6) contains a drying agent. As soon as the black protection is removed, the reservoir must be mounted in the base (8), otherwise there is a risk of damaging the air conditioning circuit. Screwing the reservoir (6) into the base (8). - Screw the reservoir (6) manually, until the neck of the reservoir (6) is in contact with the bottom of the base (8). - Tighten with a torque spanner and tool [2] at (2) to 1.3 0,1 m.daN. Fitting the plastic bracket. (New, from the replacement parts kit). Proceed in the opposite order to removal, tighten the screw (3) to 0.15 m.daN.

C5HP16EC

228

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)


Compressor lubricant. ESSENTIAL: The compressor lubricant is extremely hygroscopic; always use FRESH oil. Checking the compressor oil level. There are three specific cases : - 1/ Repairs to a system without leaks. - 2/ Slow leak. - 3/ Fast leak.

ALL TYPES

1/ Repairing a system without leaks. a) - Using draining/recovery equipment not fitted with an oil decanter. - Drain the system as slowly as possible via the LOW PRESSURE valve, so as not to lose any oil. - No more oil should be added when filling the system with R 134.a fluid. b) - Using draining/filling equipment fitted with an oil decanter. - Drain the R 134.a fluid from the system in accordance with the instructions in the equipment handbook. - Measure the amount of oil recovered. - Add the same amount of NEW oil when filling the system with R 134.a fluid. c) - Replacing a compressor. - Remove the old compressor, drain it and measure the oil quantity. - Drain the new compressor (supplied full), so that the same amount of NEW oil is left in the compressor as was in the old compressor. - No more oil should be added when filling the system with R 134.a fluid.

229

AIR CONDITIONING

AIR CONDITIONING

ALL TYPES

SPECIAL FEATURES : AIR CONDITIONING SYSTEM (R 134.a)


Checking the compressor oil level (continued)

2) Slow leak. - Slow leaks do not lead to oil loss, therefore the same procedure should be followed as if there was no leak at all. 3/ Fast leak. This type of leak causes both oil loss as well as allowing air to enter the system. It is therefore necessary to : - Replace the dryer. - Drain as much oil as possible (when replacing the faulty component). Either before or during filling of the system with R 134.a fluid, introduce 80 cc of NEW oil into the system.

230

CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM CHECKING TEMPERATURES.


TOOLS Two thermometers. Preliminary conditions. Position of the air conditioning controls : - Maximum cold air. - Air blower in maximum position. - Air distributor in "ventilation" position, with the dashboard vents open. - Air intake flap in "exterior air" position. Conditions and vehicle equipment. - Bonnet closed. - Doors and windows shut. - Ensure the vehicle is in a sheltered area (away from wind, sun, etc..). CHECKS.

ALL TYPES

If all these conditions are met, take the following action : - Start the engine, with the air conditioning off, and wait for the cooling fan first speed to cut in. - Operate the air conditioning and set the engine speed to 2500 rpm. NOTE : If the exterior temperature reaches 40 C, the engine speed will return to 2000 rpm in order to prevent the compressor from being cut off by the High Pressure safety device (Pressostat). After the air conditioning has been on for three minutes, measure : - the exterior temperature in the workshop, - the temperature of the air coming out of the central vents. Compare the two values using the table overleaf.

231

AIR CONDITIONING

AIR CONDITIONING

SYNERGIE

CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM


CHECKING TEMPERATURES. (continued)

Vehicle using R134.a fluid (Compressor with variable capacity) Exterior temperature in C Vehicles Temperature in C at the central vents SYNERGIE 12 3 83 40 35 30 25 20 15

(*) At exterior temperature 20C, air temperature from the central vents is for second speed of the ventilator fan. If fan operates at first speed, then air temperature from the central vents becomes 8.4 3 C. NOTE : In general, the temperature of the air being blown from the central vents should be around 5C to 8C. 232

CHECKING THE EFFICIENCY OF THE AIR CONDITIONING SYSTEM


CHECKING PRESSURES TOOLS : 1 Charging station and 2 Thermometers. Observing the preliminary conditions, as well as vehicle equipment and checks (see page 231) : After the air conditioning has been operating for three minutes, record the following parameters :

ALL TYPES

- The temperature of the air coming out of the central vents (See the table on page 288). - The High Pressure. - The Low Pressure. Compare the values recorded with the table below, or the graphs.

Exterior temperature in C Vehicles High pressure (Bars) Low pressure (Bars) SYNERGIE

40

Vehicle using R134.a fluid (Compressor with variable capacity) 35 30 25 20 15 16 3 2.1 0.3 13 3 1.8 0.3

233

AIR CONDITIONING

AIR CONDITIONING

C5

AIR CONDITIONING SYSTEM R 134.a


Engines : 6FZ - RFN - RLZ

(1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Capacity.

(a) Condenser bracket Tighten to 0,8 m.daN (b) Pressure control valve Tighten to 0,8 m.daN (c) Compressor bracket Tighten to 2,5 0,1 m.daN (d) Condenser dryer reservoir Tighten to 1,4 0,2 m.daN.

C5HP15QP

234

AIR CONDITIONING SYSTEM R 134.a


Engine : XFX

C5

(1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Capacity.

(a) Condenser bracket Tighten to 0,8 m.daN (b) Pressure control valve Tighten to 0,8 m.daN (c) Compressor bracket Tighten to 2,5 0,1 m.daN (d) Condenser dryer reservoir Tighten to 1,4 0,2 m.daN.

C5HP15RP

235

AIR CONDITIONING

AIR CONDITIONING

C5

AIR CONDITIONING SYSTEM R 134.a


Engines : RHY - RHZ

(1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Capacity.

(a) Condenser bracket Tighten to 0,8 m.daN (b) Pressure control valve Tighten to 0,8 m.daN (c) Compressor bracket Tighten to 2,5 0,1 m.daN (d) Condenser dryer reservoir Tighten to 1,4 0,2 m.daN.

C5HP15SP

236

AIR CONDITIONING SYSTEM R 134.a


Engine : 4HX

C5

(1) High pressure valve. (2) Low pressure valve. (3) Pressostat. (4) Capacity.

(a) Condenser bracket Tighten to 0,8 m.daN (b) Pressure control valve Tighten to 0,8 m.daN (c) Compressor bracket Tighten to 2,5 0,1 m.daN (d) Condenser dryer reservoir Tighten to 1,4 0,2 m.daN.

C5HP15TP

237

AIR CONDITIONING

AIR CONDITIONING

SYNERGIE - XU - EW10

AIR CONDITIONING SYSTEM R 134.a

C5HP12EC

Tightening torques. (1) (2) (3) (4) (5) High pressure valve Low pressure valve Pressostat, tighten to 1,8 m.daN Dryer Clickfit union.

C5HP15PP

a) 0,8 m.daN b) 4 m.daN c) 0,8 m.daN 238

AIR CONDITIONING SYSTEM R 134.a

SYNERGIE - DW10

C5HP12EC

Tightening torques. (1) (2) (3) (4) (5) (6) (7)


C5HP15EP

High pressure valve Low pressure valve Clickfit union. Pressostat, tighten to 1,8 m.daN Flange fixing, tighten to 0,8 m.daN. Flange fixing, tighten to 0,8 m.daN. Flange fixing, tighten to 4 m.daN.

239

AIR CONDITIONING

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